U.S. patent application number 17/674631 was filed with the patent office on 2022-06-02 for high density, high speed electrical connector.
This patent application is currently assigned to Amphenol Corporation. The applicant listed for this patent is Amphenol Corporation. Invention is credited to Marc B. Cartier, JR., John Robert Dunham, Mark W. Gailus, John Pitten.
Application Number | 20220173534 17/674631 |
Document ID | / |
Family ID | |
Filed Date | 2022-06-02 |
United States Patent
Application |
20220173534 |
Kind Code |
A1 |
Cartier, JR.; Marc B. ; et
al. |
June 2, 2022 |
HIGH DENSITY, HIGH SPEED ELECTRICAL CONNECTOR
Abstract
A modular high speed, high density electrical connector
configurable for use in multiple configurations, including a direct
attach orthogonal configuration. The connector is assembled with
modules that include shielded pairs of signal conductors with
mating ends that are rotated approximately 45 degrees with respect
to intermediate portions of the signal conductors. The connector
may have a mating interface with receptacles in one connector and
pins in the mating connector. The pins may be small diameter and
may be implemented with superelastic wires so as to resist damage
despite having very small effective diameter. A compact mating
interface resulting from small diameter mating contact portions may
enable other portions of the connector, including the shielding
surrounding the signal conductors to be smaller, which may raise
the resonant frequency of the connector and extend its
bandwidth.
Inventors: |
Cartier, JR.; Marc B.;
(Durham, NH) ; Dunham; John Robert; (Windham,
NH) ; Gailus; Mark W.; (Concord, MA) ; Pitten;
John; (Merrimack, NH) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Amphenol Corporation |
Wallingford |
CT |
US |
|
|
Assignee: |
Amphenol Corporation
Wallingford
CT
|
Appl. No.: |
17/674631 |
Filed: |
February 17, 2022 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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16878558 |
May 19, 2020 |
11289830 |
|
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17674631 |
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62850391 |
May 20, 2019 |
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International
Class: |
H01R 9/24 20060101
H01R009/24; H01R 13/6585 20060101 H01R013/6585 |
Claims
1. A wafer, comprising: a plurality of signal conductor pairs, each
signal conductor pair comprising a pair of mating ends, a pair of
contact tails and a pair of intermediate portions connecting the
pair of mating ends to the pair of contact tails, wherein: the
pairs of mating ends of the plurality of signal conductor pairs are
positioned in a column along a column direction; the intermediate
portions of the pairs of intermediate portions of the plurality of
signal conductor pairs are aligned in a direction perpendicular to
the column direction and positioned for broadside coupling; and the
mating ends of the plurality of signal conductor pairs are
separated along lines disposed at an angle of greater than 0
degrees and less than 90 degrees relative to the column
direction.
2. The wafer of claim 1, wherein: the lines are disposed at an
angle of greater than 30 degrees and less than 60 degrees relative
to the column direction.
3. The wafer of claim 1, wherein the lines are disposed at an angle
of 45 degrees relative to the column direction.
4. The wafer of claim 3, further comprising a housing supporting
the plurality of signal conductor pairs.
5. The wafer of claim 3, wherein each of the plurality of signal
conductor pairs comprises a plurality of connector modules, each
connector module of the plurality of connector modules further
comprised of: electromagnetic shielding disposed around the signal
conductor pair, wherein portions of the electromagnetic shielding
at least partially surrounds the mating ends of the signal
conductors of the signal conductor pair and is rectangular with a
width less than 2 mm and a length less than 3.8 mm.
6. The wafer of claim 5, wherein: the housing comprises a first
housing member comprising a plurality of grooves; and a connector
module of the plurality of connector modules is disposed within a
groove of the plurality of grooves.
7. The wafer of claim 6, wherein the housing is formed of a lossy
conductive material.
8. The wafer of claim 3, wherein: the column direction is a mating
interface column direction; the pairs of contact tails of the
plurality of signal conductor pairs are positioned in a column
along a mounting interface column direction; and contact tails of
the pairs of contact tails are separated in a mounting interface
row direction perpendicular to the mounting interface column
direction.
9. The wafer of claim 8, wherein the mating interface column
direction is orthogonal to the mounting interface column
direction.
10. The wafer of claim 8, wherein center-to-center spacing between
adjacent pairs of contact tails in the mounting interface column
direction is less than or equal to 5 mm.
11. The wafer of claim 8, wherein center-to-center spacing between
adjacent pairs of contact tails in the mounting interface column
direction is less than or equal to 2.4 mm.
12. The wafer of claim 8, wherein the mounting interface row
direction is orthogonal to the mounting interface column
direction.
13. The wafer of claim 3, wherein the pairs of contact tails are
configured to be inserted into holes having a diameter of less than
or equal to 20 mils.
14. The wafer of claim 13, wherein each contact tail of the pairs
of contact tails has a width between 6 and 20 mils.
15. The wafer of claim 3, wherein the pairs of contact tails are
configured to be inserted into holes having a diameter of less than
or equal to 10 mils.
16. The wafer of claim 15, wherein each contact tail of the pairs
of contact tails has a width between 6 and 10 mils.
17. A connector comprising: an insulative portion; a plurality of
signal conductors held by the insulative portion; and a plurality
of shielding members, wherein: the plurality of signal conductors
comprise elongated mating portions extending from the insulative
portion; the plurality of signal conductors comprise a plurality of
pairs of signal conductors disposed in a plurality of rows
extending in a row direction; the plurality of shielding members at
least partially surround pairs of the plurality of pairs; and the
mating portions of the plurality of pairs are separated along first
parallel lines disposed an angle of greater than 0 degrees and less
than 90 degrees relative to the row direction.
18. The connector of claim 17, wherein the first parallel lines are
disposed at an angle of greater than 30 degrees and less than 60
degrees relative to the row direction.
19. The connector of claim 17, wherein the first parallel lines are
disposed at an angle of 45 degrees relative to the row
direction.
20. The connector of claim 17, wherein the plurality of shielding
members comprise electrically conductive sheets.
21. The connector of claim 17, wherein: the insulative portion
comprises a planar portion having a first surface and a second
surface, opposite the first surface; the mating portions extend in
a direction perpendicular to the first surface; the signal
conductors further comprise contact tails that extend through the
second surface.
22. The connector of claim 21, wherein the contact tails are
disposed in a second plurality of rows extending in a first
direction and positioned along a second direction perpendicular to
the first direction in a repeating pattern with: center-to-center
spacing between adjacent pairs of contact tails in the first
direction is less than or equal to 5 mm; and center-to-center
spacing between adjacent pairs of contact tails in the second
direction perpendicular to the first direction is less than or
equal to 5 mm.
23. The connector of claim 21, wherein the contact tails are
disposed in a second plurality of rows extending in a first
direction and positioned along a second direction perpendicular to
the first direction in a repeating pattern with: center-to-center
spacing between adjacent pairs of contact tails in the first
direction is less than or equal to 2.4 mm; and center-to-center
spacing between adjacent pairs of contact tails in the second
direction perpendicular to the first direction is less than or
equal to 2.4 mm.
24. The connector of claim 21, wherein the contact tails are
configured for inserting into holes having a diameter of less than
or equal to 20 mils.
25. The connector of claim 24, wherein the contact tails have a
width of between 6 and 20 mils.
26. The connector of claim 21, wherein the contact tails are
configured for inserting into holes having a diameter of less than
or equal to 10 mils.
27. The connector of claim 24, wherein the contact tails have a
width of between 6 and 10 mils.
28. The connector of claim 17, wherein: the plurality of pairs of
signal conductors further comprise intermediate portions connected
to the mating portions by transition regions; signal conductors of
each pair of signal conductors are separated along the first
parallel lines at a first portion of the transition region adjacent
the mating portions; and the signal conductors are separated along
second parallel lines parallel to the row direction at a second
portion of the transition region adjacent the intermediate
portions.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. application Ser.
No. 16/878,558, filed on May 19, 2020, under Attorney Docket No.
A0863.70120US01, entitled "HIGH DENSITY, HIGH SPEED ELECTRICAL
CONNECTOR," which claims the benefit under 35 U.S.C. .sctn. 119(e)
of U.S. Provisional Patent Application Ser. No. 62/850,391, filed
on May 20, 2019, under Attorney Docket No. A0863.70120US00,
entitled "HIGH DENSITY, HIGH SPEED ELECTRICAL CONNECTOR," which is
hereby incorporated herein by reference in its entirety.
BACKGROUND
[0002] This patent application relates generally to interconnection
systems, such as those including electrical connectors, used to
interconnect electronic assemblies.
[0003] Electrical connectors are used in many electronic systems.
It is generally easier and more cost effective to manufacture a
system as separate electronic assemblies, such as printed circuit
boards ("PCBs"), which may be joined together with electrical
connectors. A known arrangement for joining several printed circuit
boards is to have one printed circuit board serve as a backplane.
Other printed circuit boards, called "daughterboards" or
"daughtercards," may be connected through the backplane.
[0004] A known backplane is a printed circuit board onto which many
connectors may be mounted. Conducting traces in the backplane may
be electrically connected to signal conductors in the connectors so
that signals may be routed between the connectors. Daughtercards
may also have connectors mounted thereon. The connectors mounted on
a daughtercard may be plugged into the connectors mounted on the
backplane. In this way, signals may be routed among the
daughtercards through the backplane. The daughtercards may plug
into the backplane at a right angle. The connectors used for these
applications may therefore include a right angle bend and are often
called "right angle connectors."
[0005] Connectors may also be used in other configurations for
interconnecting printed circuit boards. Some systems use a midplane
configuration. Similar to a backplane, a midplane has connectors
mounted on one surface that are interconnected by routing channels
within the midplane. The midplane additionally has connectors
mounted on a second side so that daughter cards are inserted into
both sides of the midplane.
[0006] The daughter cards inserted from opposite sides of the
midplane often have orthogonal orientations. This orientation
positions one edge of each printed circuit board adjacent the edge
of every board inserted into the opposite side of the midplane. The
traces within the midplane connecting the boards on one side of the
midplane to boards on the other side of the midplane can be short,
leading to desirable signal integrity properties.
[0007] A variation on the midplane configuration is called "direct
attach." In this configuration, daughter cards are inserted from
opposite sides of the system. These boards likewise are oriented
orthogonally so that the edge of a board inserted from one side of
the system is adjacent to the edges of the boards inserted from the
opposite side of the system. These daughter cards also have
connectors. However, rather than plug into connectors on a
midplane, the connectors on each daughter card plug directly into
connectors on printed circuit boards inserted from the opposite
side of the system.
[0008] Connectors for this configuration are sometimes called
orthogonal connectors. Examples of orthogonal connectors are shown
in U.S. Pat. Nos. 7,354,274, 7,331,830, 8,678,860, 8,057,267 and
8,251,745.
BRIEF SUMMARY
[0009] Embodiments of a high density, high speed electrical
connector and associated modules and assemblies are described. In
accordance with some embodiments, a connector module may comprise a
pair of signal conductors, the pair of signal conductors comprising
a pair of mating ends, a pair of contact tails and a pair of
intermediate portions connecting the pair of mating ends to the
pair of contact tails, the pair of mating ends being elongated in a
direction that is at a right angle relative to a direction in which
the pair of contact tails are elongated, the mating ends of the
pair of mating ends being separated in a direction of a first line,
the intermediate portions of the pair of intermediate portions
being separated in a direction of a second line, and the first line
being disposed at an angle greater than 0 degrees and less than 90
degrees relative to the second line.
[0010] In accordance with some embodiments, a wafer may comprise a
plurality of signal conductor pairs, each signal conductor pair
comprising a pair of mating ends, a pair of contact tails and a
pair of intermediate portions connecting the pair of mating ends to
the pair of contact tails, the pairs of mating ends of the
plurality of signal conductor pairs being positioned in a column
along a column direction, the intermediate portions of the pairs of
intermediate portions of the plurality of signal conductor pairs
being aligned in a direction perpendicular to the column direction
and positioned for broadside coupling, and the mating ends of the
plurality of signal conductor pairs being separated along lines
disposed at an angle of greater than 0 degrees and less than 90
degrees relative to the column direction.
[0011] In accordance with some embodiments, a connector may
comprise a plurality of signal conductor pairs, where, for each
signal conductor pair of the plurality of signal conductor pairs,
the signal conductor pair comprises a pair of mating ends, a pair
of contact tails, and a pair of intermediate portions connecting
the pair of mating ends to the pair of contact tails, the signal
conductor pair further comprises a transition region between the
pair of mating ends and the pair of intermediate portions, the
pairs of mating ends of the plurality of signal conductor pairs are
disposed in an array comprising a plurality of rows, the plurality
of rows extending along a row direction and spaced from each other
in a column direction perpendicular to the row direction, the pairs
of mating ends of the plurality of signal conductor pairs are
aligned along first parallel lines that are disposed at an angle of
greater than 0 degrees and less than 90 degrees relative to the row
direction, and, for each signal conductor pair of the plurality of
signal conductor pairs, within the transition region, a relative
position of the signal conductors of the signal conductor pair
varies such that, at a first end of the transition region adjacent
the mating end, the signal conductors are aligned along a line of
the first parallel lines and at a second end of the transition
region the signal conductors are aligned in the row direction.
[0012] In accordance with some embodiments, a connector module may
comprise an insulative member and a pair of signal conductors held
by the insulative member, each signal conductor of the pair of
signal conductors comprises a first portion at a first end, a
second portion at a second end extending from the insulative
portion and an intermediate portion disposed between the first and
second ends, and the first portion comprises a wire with a diameter
between 5 and 20 mils.
[0013] In accordance with some embodiments, an extender module may
comprise a pair of signal conductors, each signal conductor of the
pair of signal conductors comprising a first portion at a first end
and a second portion at a second end and electromagnetic shielding
at least partially surrounding the pair of signal conductors, the
first portions of the pair of signal conductors being configured as
mating portions and are positioned along a first line, and the
second portions of the pair of signal conductors being configured
to compress upon insertion into a hole and are positioned along a
second line parallel to the first line.
[0014] In accordance with some embodiments, a connector may
comprise an insulative portion, a plurality of signal conductors
held by the insulative portion, and a plurality of shielding
members, the plurality of signal conductors comprising elongated
mating portions extending from the insulative portion, the
plurality of signal conductors comprising a plurality of pairs of
signal conductors disposed in a plurality of rows extending in a
row direction, the plurality of shielding members at least
partially surrounding pairs of the plurality of pairs, and the
mating portions of the plurality of pairs being separated along
first parallel lines disposed an angle of 45 degrees relative to
the row direction.
BRIEF DESCRIPTION OF DRAWINGS
[0015] The accompanying drawings are not intended to be drawn to
scale. In the drawings, each identical or nearly identical
component that is illustrated in various figures is represented by
a like numeral. For purposes of clarity, not every component may be
labeled in every drawing. In the drawings:
[0016] FIG. 1 is a perspective view of mated, direct attach
orthogonal connectors, in accordance with some embodiments;
[0017] FIG. 2A is a perspective view of electrical connector 102a
of FIG. 1 having extender modules;
[0018] FIG. 2B is a perspective view of electrical connector 102b
of FIG. 1;
[0019] FIG. 3A is a front view of an electrical connector having an
extender module assembly, in accordance with an alternative
embodiment;
[0020] FIG. 3B is a front view of an electrical connector
configured to mate with the connector of FIG. 3A;
[0021] FIG. 3C is a front view of an electrical connector having an
extender module assembly, in accordance with a further alternative
embodiment;
[0022] FIG. 3D is a front view of an electrical connector
configured to mate with the connector of FIG. 3C;
[0023] FIG. 4 is a partially exploded view of electrical connector
102a of FIG. 1;
[0024] FIG. 5 is a perspective view of electrical connector 102a of
FIG. 4 with a single extender module;
[0025] FIG. 6 is an exploded view of electrical connector 102b of
FIG. 1;
[0026] FIG. 7 is a partially exploded view of an electrical
connector with front housing removed and with a compliant shield
member, in accordance with some embodiments;
[0027] FIG. 8 is a plan view of a portion of a printed circuit
board illustrating routing channels in a footprint for mounting an
electrical connector, in accordance with some embodiments;
[0028] FIG. 9A is a perspective view of electrical connector 102 of
FIG. 7 with front housing cut away and having retaining members, in
accordance with some embodiments;
[0029] FIG. 9B is a perspective view of a first retaining member
180 of FIG. 9A;
[0030] FIG. 9C is an alternate perspective view of the retaining
member 180 of FIG. 9B;
[0031] FIG. 10A is a perspective view of wafer 130 of electrical
connector 102 illustrated in FIG. 7;
[0032] FIG. 10B is a perspective view of wafer 130 of FIG. 10A with
a wafer housing member 133b cut away;
[0033] FIG. 11 is a plan view of an housing member 133a and one
connector module 200 of wafer 130 of FIG. 10A;
[0034] FIG. 12A is a side view of connector module 200 of FIG.
11;
[0035] FIG. 12B is a perspective view of connector module 200 of
FIG. 11;
[0036] FIG. 12C is an alternate perspective view of connector
module 200 of FIG. 11;
[0037] FIG. 13A is a side view of connector module 200 of FIG. 11
with electromagnetic shielding members 210 cut away;
[0038] FIG. 13B is a perspective view of connector module 200 of
FIG. 13A;
[0039] FIG. 13C is an alternative side view of connector module 200
of FIG. 13A;
[0040] FIG. 14A is a side view of connector module 200 of FIG. 11
with electromagnetic shielding members 210 as well as outer
insulative members 180a and 180b cut away;
[0041] FIG. 14B is a perspective view of connector module 200 of
FIG. 14A;
[0042] FIG. 14C is an alternative side view of connector module 200
of FIG. 14A;
[0043] FIG. 15 is a perspective view of inner insulative member 230
of connector module 200 of FIGS. 14A-C;
[0044] FIG. 16A is a side view of signal conductors 260a and 260b
of connector module 200 of FIG. 14A-C;
[0045] FIG. 16B is a perspective view of signal conductors 260a and
260b of FIG. 16A;
[0046] FIG. 16C is an alternative side view of signal conductors
260a and 260b of FIG. 16A;
[0047] FIG. 17A is a perspective view of connector module 200 of
FIG. 11 with extender module 300 of FIG. 5;
[0048] FIG. 17B is a perspective view of connector module 200 and
extender module 300 of FIG. 17A, with electromagnetic shielding
members 210a and 210b cut away;
[0049] FIG. 17C is a perspective view of signal conductors 260 of
connector module 200 and extender module of FIG. 17C;
[0050] FIG. 18A is a perspective view of extender module 300 of
FIG. 5;
[0051] FIG. 18B is a side view of extender module 300 of FIG.
18A;
[0052] FIG. 18C is an alternative side view of extender module 300
of FIG. 18A;
[0053] FIG. 19A is a side view of extender module 300 of FIG. 18A,
with electromagnetic shielding members 310a and 310b cut away from
the extender module;
[0054] FIG. 19B is a side view of the extender module of FIG.
19A;
[0055] FIG. 20A is a side view of signal conductors 302a and 302b
of extender module 300 of FIG. 18A;
[0056] FIG. 20B is an alternative side view of signal conductors
302a and 302b of FIG. 20A;
[0057] FIG. 21A is a perspective view of a header connector;
[0058] FIG. 21B is a perspective view of a connector module of the
header connector of FIG. 21A;
[0059] FIG. 22 is a perspective view of an alternative
configuration of a connector in which some connector modules are
configured for attachment to a printed circuit board and other
connector modules are terminated to a cable; and
[0060] FIG. 23 is a perspective view of signal conductors of an
alternative embodiment of a pair of signal conductors.
DETAILED DESCRIPTION
[0061] The inventors have developed techniques for making
electrical connectors for high speed signals and having high
density and that can be manufactured with low cost. These
techniques include arrangements of mating interfaces to simply
support multiple configurations, including right angle or direct
mate orthogonal system configurations or system configurations with
cabled connections to mid-board components. The configurations also
may provide signal paths with low mode conversion and reduce other
electrical effects that may impact signal integrity.
[0062] The inventors have recognized and appreciated that
electrical connectors with angled mating interfaces (e.g., with
mating ends of pairs of signal conductors twisted with respect to
intermediate portions of the signal conductors) provide enhanced
flexibility in making connections between connectors having direct
mate orthogonal, backplane, or other configurations. Such an angled
mating interface may be created, for example, in a connector in
which signal conductors are routed in pairs and the mating ends of
a pair are separated along a first line and the intermediate
portions of the pair are separated along a second line that makes
an angle more than 0 degrees but less than 90 degrees relative to
the first line. Two connectors with similar angled interfaces may
be used as part of a direct mate orthogonal connector system. Such
connectors may be mated via extender modules that have
straight-through signal paths, which are easy to manufacture. As a
result of this use of similar, or even identical, connectors that
are mated via simple extender modules, the cost of the
interconnection system may be low.
[0063] In some embodiments, the angled interfaces of two mating
connectors may be angled at the same angle with respect to a normal
to the mating face of the connector. In some embodiments, the
angles of the two mating connectors may have the same magnitude but
may be in the opposite direction. The specific angle and direction
for each connector may depend on the system configuration. As a
specific example, for connectors designed for direct mate
orthogonal configurations, the mating connectors may both have
mating interfaces angled at 45 degrees in clockwise direction. For
a parallel board configuration, the mating connectors may both have
mating interfaces angled at 45 degrees, but in one direction the
angle may be in a clockwise direction and in the other connector,
the mating interface may be angled in a counter-clockwise
direction. These angles may be described as 45 degrees and 135
degrees respectively, where the angle of both connectors is
measured in a clockwise direction.
[0064] An interconnection system as described herein may provide
for high signal integrity, as mode conversion may be low as a
result of limiting twists in pairs of signal paths to be less than
90 degrees. The inventors have also recognized and appreciated that
using connectors with angled mating interfaces reduces the angular
amount of twist of the conductors of a signal pair over a signal
path, which enables the rate of angular twist to be low. Lowering
the rate of angular twist improves integrity of signals carried by
the connector system by reducing skew and/or mode conversion
associated with the twist, even in a miniaturized connector. The
resulting rate of angular twist in at least one transition region
may be about 45 degrees per 1.5 mm or less, in some embodiments,
which may provide low mode conversion in the transition region. In
some embodiments, the rate of angular twist in a transition region
between intermediate portions of signal conductors, which may be
aligned broadside to broadside, and mating interface portions of
the signal conductors may be, for example, in a range of 45 to 90
degrees per mm or 45 to 80 degrees per mm.
[0065] An angled interface may also enable simple designs of
extender modules that may be attached to a connector to alter the
position, orientation or mating contact type of the mating
interface of the connector. Such extender module designs allow for
a single type of connector to be used on both sides of an
interconnect system, with extender modules providing an interface
between the connectors. The extender modules may have signal
conductors that pass through the module without a twist, which
enables the extender module to be substantially encircled by a
shield formed from one sheet, or a small number of sheets, of metal
that may be cut and folded to partially or fully surround the
module.
[0066] These techniques also include the use of thin signal
conductors in portions of the connector, such as in the mating
interface and/or mounting interface. As a result, ground
conductors, such as may be used to provide shielding around signal
conductors or pairs of signal conductors, may bound small cavities
that contain signal conductors or signal conductor pairs. As a
result of the small cavities, resonances, which might interfere
with high integrity operation of the connector, occur at a high
frequency, which may be outside the desired operating frequency
range of the connector. In some embodiments, the ground conductor
surrounding a signal pair may bound a cavity that has a rectangular
cross section and the longer dimension of that cavity may be
reduced so as to increase the frequency of the lowest frequency
resonance supported by that cavity. In some embodiments, thin
signal conductors may be implemented with superelastic conductive
materials. At least the mating contact portions of the signal
conductors may be formed of superelastic conductive materials, such
as superelastic wires, which may have small diameters but suitable
mechanical integrity.
[0067] The inventors have recognized and appreciated that the shape
and location of features in electromagnetic shields, including near
mating ends of signal conductor pairs, may reduce impedance
discontinuities associated with variability in spacing between
mated connectors. Such features may include inwardly projecting
portions of a shield adjacent the mating ends.
[0068] These techniques may be used separately or together, in any
suitable combination. As a result of the improved electrical
properties achieved by these techniques, electrical connectors
described herein may be configured to operate with high bandwidth
for a high data transmission rate. For example, electrical
connectors described herein may operate at 40 GHz or above and may
have a bandwidth of at least 50 GHz, such as a frequency up to and
including 56 GHz and/or a bandwidth in the range of 50-60 GHz. Such
electrical connectors may pass data at rates up to 112 Gb/s, for
example.
[0069] Turning to the figures, FIGS. 1 and 2A-B illustrate
electrical connectors of an electrical interconnect system in
accordance with some embodiments. FIG. 1 is a perspective view of
electrical interconnect system 100 including first and second mated
connectors, here configured as direct attach orthogonal connectors
102a and 102b. FIG. 2A is a perspective view of electrical
connector 102a, and FIG. 2B is a perspective view of electrical
connector 102b, showing mating interfaces and mounting interfaces
of those connectors. In the embodiment illustrated, the mating
interfaces are complementary such that connector 102a mates with
connector 102b. The mounting interfaces, in the embodiment
illustrated, are similar, as each comprises an array of press fit
contact tails configured for mounting to a printed circuit
board.
[0070] Electrical connectors 102a and 102b may be manufactured
using similar techniques and materials. For example, electrical
connector 102a and 102b may include wafers 130 that are
substantially the same. Electrical connectors 102a and 102b having
wafers 130 that may be manufactured and/or assembled in a same
process may have a low manufacturing cost.
[0071] In the embodiment illustrated in FIG. 1, first connector
102a includes first wafers 130a, including one or more individual
wafers 130 positioned side-by-side. Wafers 130 are described
herein, including with reference to FIG. 10A. Wafers 130 include
one or more connector modules 200, described further herein,
including with reference to FIG. 10B.
[0072] Wafers 130 also include wafer housings 132a that hold the
connector modules 200. The wafers are held together, side-by-side,
such that contact tails extending from the wafers 130 of first
connector 102a form first contact tail array 136a. Contact tails of
first contact tail array 136a may be configured for mounting to a
substrate, such as substrate 104c described in connection with FIG.
3A. For example, first contact tail array 136 may be configured for
press-fit insertion, solder mount, or any other mounting
configuration, either for mounting to a printed circuit board or to
conductors within an electrical cable.
[0073] In the illustrated embodiment, first connector 102a includes
extender housing 120, within which are extender modules 300,
described further herein including with reference to FIG. 2A. In
the illustrated embodiment, first connector 102a includes signal
conductors that have contact tails forming a portion of first
contact tail array 136a. The signal conductors have intermediate
portions joining the contact tails to mating ends. In the
illustrated embodiment, the mating ends are configured to mate with
further signal conductors in the extender modules 300. The signal
conductors in extender modules 300 likewise have mating ends, which
form the mating interface of connector 102a visible in FIG. 2A.
Ground conductors similarly extend from wafers 130a, through the
extender modules 300, to the mating interface of connector 102a
visible in FIG. 2A.
[0074] Second connector 102b includes second wafers 130b, including
one or more wafers 130 positioned side-by-side. Wafers 130 of
second wafers 130b may be configured as described for first wafers
130a. For example, wafers 130 of second wafers 130b have wafer
housings 132b. Additionally, second contact tail array 136b of
second connector 102b is formed of contact tails of conductive
elements within second wafers 130b. As with first contact tail
array 136a, second contact tail array 136b may be configured for
press-fit insertion, solder mount, or any other mounting
configuration, either for mounting to a printed circuit board or to
conductors within an electrical cable.
[0075] As shown in FIG. 1, first contact tail array 136a faces a
first direction and second contact tail array 136b faces a second
direction perpendicular to the first direction. Thus, when first
contact tail array 136a is mounted to a first substrate (such as a
printed circuit board) and second contact tail array 136b is
mounted to substrate 104d, surfaces of the first and second
substrates may be perpendicular to one another. Additionally, first
connector 102a and second connector 102b mate along a third
direction perpendicular to each of the first and second directions.
During the process of mating first connector 102a with second
connector 102b, one or both of first and second connectors 102a and
102b move towards the other connector along the third
direction.
[0076] It should be appreciated that, while first and second
electrical connectors 102a and 102b are shown in a direct attach
orthogonal configuration in FIG. 1, connectors described herein may
be adapted for other configurations. For example, connectors
illustrated in FIGS. 3C to 3D have mating interfaces angled in
opposite directions and may be used for a co-planar configuration.
FIG. 21 illustrates that construction techniques as described
herein may be used in a backplane, midplane, or mezzanine
configuration. However, it is not a requirement that the mating
interface be used in board to board configuration. FIG. 22
illustrates that some or all of the signal conductor's within a
connector may be terminated to cables, creating a cable connector
or hybrid cable connector. Other configurations are also
possible.
[0077] As shown in FIG. 2A, first electrical connector 102a also
includes extender modules 300, which provide a mating interface for
first connector 102a. For example, mating portions of extender
modules 300 form first mating end array 134a. Additionally,
extender modules 300 may be mounted to connector modules 200 of
first wafers 130a, as described further herein including with
reference to FIG. 17A. Extender housing 120 holds extender modules
300, surrounding at least a portion of the extender modules 300.
Here, extender housing 120 surrounds the mating interface and
includes grooves 122 for receiving second connector 102b. Extender
housing 120 also includes apertures through which extender modules
300 extend, as described herein including with reference to FIG.
4.
[0078] As shown in FIG. 2B, second electrical connector 102b has a
front housing 110b shaped to fit within an opening in extender
housing 120. Second wafers 130b are attached to front housing 110b,
as described further herein, including with reference to FIG.
6.
[0079] Front housing 110b provides a mating interface for second
connector 102b. For example, front housing 110b includes
projections 112 which are configured to be received in grooves of
extender housing 120. Mating ends of signal conductors of wafers
130b are exposed within apertures 114b of front housing 110b,
forming second mating end array 134b, such that the mating ends may
engage with signal conductors of the wafers 130a of first connector
102a. For example, extender modules 300 extend from first connector
102a and may be received by the pairs of signal conductors of
second connector 102b. Ground conductors of wafers 130b are
similarly exposed within apertures 114b and may similarly mate with
ground conductors in the extender modules 300, which in turn are
connected to ground conductors in wafers 130a.
[0080] In FIGS. 2A-B, first connector 102a is configured to receive
second connector 102b. As illustrated, grooves 122 of extender
housing 120 are configured to receive projections of front housing
110b. Additionally, apertures 114b are configured to receive mating
portions of extender modules 300.
[0081] It should be appreciated that second wafers 130a of first
connector 102a and second wafers 130b of second connector 102b may
be substantially identical, in some embodiments. For example, first
connector 102a may include front housing 110a, which may receive
wafers from one side, and which may be configured similarly to a
corresponding side of front housing 110b. An opposite side of front
housing 110a may be configured for attachment to extender housing
120 such that front housing 110a is disposed between first wafers
130a and extender housing 120. Front housing 110a is described
further herein, including with reference to FIG. 4.
[0082] Front housing 110b may be configured to mate with extender
housing 120. In some embodiments, extender housing 120 may be
configured such that features that might latch to features if
inserted into one side of extender housing 120 would slide in an
out, to support separable mating, if inserted in an opposite side
of extender housing 120. In such a configuration the same component
could be used for front housing 110a or front housing 110b. The
inventors have recognized and appreciated that using extender
modules to interface between identical connectors allows for
manufacturing of a single type of connector to be used on each side
of an electrical interconnect system, thus reducing a cost of
producing the electrical interconnect system. Even if front housing
110a and front housing 110b are shaped differently to support
either a fixed attachment to extender housing 120 or a sliding
engagement to extender housing 120, efficiencies are achieved by
using wafers that can be made with the same tooling in both
connectors 102a and 102b. Similar efficiencies may be achieved in
other configurations, for example, if front housing 110a and
extender housing 120 are made as a single component.
[0083] Electrical connectors as described herein may be formed with
different numbers of signal conductors than shown in FIGS. 2A and
2B. FIG. 3A is a front view of third electrical connector 102c
mounted to substrate 104c and having extender housing 120c, in
accordance with an alternative embodiment. Although third
electrical connector 102c is illustrated having fewer signal pairs
than first electrical connector 102a, third electrical connector
102c may be otherwise assembled using components as described with
reference to first electrical connector 102a. For example,
electrical connector 102c may be assembled from extender housing
120c and third wafers 130c having third mating end array 134c and
third contact tail array 136c, which may be configured in the
manner described herein with reference to extender housing 120,
first wafers 130a, first mating end array 134a, and first contact
tail array 136a.
[0084] In FIG. 3A, third electrical connector 102c is mounted to
substrate 104c. For example, third connector 102c may be a right
angle connector mounted adjacent an edge of substrate 104c. In some
embodiments, substrate 104c may comprise a printed circuit board.
In the illustrated embodiment of FIG. 3A, pairs of contact tails of
third contact tail array 136c are mounted to substrate 104c. In
some embodiments, contact tails of third contact tail array 136c
are configured for inserting into holes in substrate 104c. In some
embodiments, contact tails of third contact tail array 136c are
configured for mounting onto pads on substrate 104c, such as by
surface mount soldering techniques.
[0085] In the illustrated embodiment, pairs of mating ends of third
mating end array 134c are connected along parallel lines 138c and
are disposed at a 45 degree angle relative to each of mating column
direction 140c and mating row direction 142c.
[0086] FIG. 3B is a front view of fourth electrical connector 102d
configured to mate with third connector 102c illustrated in FIG.
3A. Although fourth electrical connector 102d is illustrated having
fewer signal pairs than second electrical connector 102b, fourth
electrical connector 102d may be otherwise configured in the manner
described with reference to second electrical connector 102d. For
example, electrical connector 102d may be assembled from front
housing 110d and fourth wafers 130d having fourth mating end array
134d and fourth contact tail array 136d. These components may be
configured in the manner described herein with reference to front
housing 110b, second wafers 130b, second mating end array 134b, and
second contact tail array 136b.
[0087] In FIG. 3B, fourth electrical connector 102d is mounted to
substrate 104d. In some embodiments, fourth connector 102d
comprises an edge connector mounted adjacent an edge of substrate
104d. Substrate 104d may comprise a printed circuit board. Contact
tails of fourth contact tail array 136d are mounted to substrate
104d. In some embodiments, contact tails of fourth contact tail
array 136d are configured for inserting into holes in substrate
104d. In some embodiments, contact tails of fourth contact tail
array 136d are configured for mounting onto pads on substrate 104d,
such as by solder mount.
[0088] Front housing 110d includes apertures 114d in which mating
ends of pairs of signal conductors of fourth wafers 130d are
positioned, enabling signal conductors from connector 102c inserted
into apertures 114d to mate with the signal conductors of fourth
wafers 130d. Ground conductors of fourth wafers 130d are similarly
exposed within apertures 114d for mating with ground conductors
from connector 102c.
[0089] Fourth mating end array 134d comprises rows extending along
row direction 142d and spaced from each other in column direction
140d perpendicular to row direction 142d. Pairs of mating ends of
fourth mating end array 134d are aligned along parallel lines 138d.
In the illustrated embodiment, parallel lines 138a are disposed at
an angle of 45 degrees relative to row direction 142d.
[0090] In the illustrated embodiment, mating ends of signal
conductors of the second wafers are connected along parallel lines
138d disposed at a 45 degree angle relative to each of mating
column direction 140d and mating row direction 142d.
[0091] Similar to connectors 102a and 102b, FIGS. 1-2, FIGS. 3A-3B
illustrate connectors 102c and 102d having a direct attach
orthogonal configuration. FIGS. 3C-3D illustrate electrical
connectors 102c' and 102d' having a co-planar configuration. When
connector 102c' is mated with connector 102d', substrate 104c' and
substrate 104d' may be co-planar. Substrates 104c' and 104d' on
which connectors 102c' and 102d' are mounted may be aligned in
parallel. In this example, connectors 102c' and 102d' differ from
connectors 102a, 102b, and 102c and 102d in that the mating
interfaces of connectors 102c' and 102d' are angled in opposite
directions whereas the mating interfaces of connectors 102a, 102b,
and 102c and 102d are angled in the same direction. Otherwise,
connectors 102c' and 102d' may be constructed in the manner
described for connectors 102a, 102b, and 102c and 102d.
[0092] Mating end arrays 134c' and 134d' may be adapted for a
co-planar configuration. Similar to FIGS. 3A-3B, mating ends of
mating end array 134c' are positioned along parallel lines 138c'
and mating ends of mating end array 134d' are positioned along
parallel lines 138d'. In FIGS. 3C-3D, parallel lines 138c' and
138d' are perpendicular to one another as mating end arrays 134c'
and 134d' are shown facing along a same direction. For example,
while a same connector may be used on both sides of the direct
attach orthogonal configuration shown in FIGS. 3A-3B, variants of a
same connector may be used in the co-planar configuration shown in
FIGS. 3C-3D.
[0093] In some embodiments, a relative position of pairs of mating
ends of mating end array 134c' may be rotated 90 degrees with
respect to the relative position of pairs of mating ends of mating
end array 134d'. In some embodiments, parallel lines 138c' may be
disposed at a counter-clockwise angle of 45 degrees (e.g., +45
degrees) relative to mating row direction 142c', and parallel lines
138d' may be disposed at a clockwise angle of 45 degrees (e.g., -45
degrees, or +135 degrees counter-clockwise) relative to mating row
direction 142d'. It should be appreciated that, alternatively,
parallel lines 138d' may be disposed at a counter-clockwise angle
of 45 degrees (e.g., +45 degrees) relative to mating row direction
142d', and parallel lines 138c' may be disposed at a clockwise
angle of 45 degrees (e.g., -45 degrees, or +135 degrees
counter-clockwise) relative to mating row direction 142c'.
[0094] FIG. 4 is a partially exploded view of electrical connector
102a of FIG. 1. In this illustrated embodiment of FIG. 4, extender
housing 120 is shown removed from front housing 110a to show front
housing 110a and an array of extender modules 300.
[0095] In the illustrated embodiment, front housing 110a is
attached to wafers 130. Front housing 110a may be formed using a
dielectric such as plastic, for example in one or more molding
processes. Also as shown, front housing 110a includes projections
112a, which are here configured for latching front housing 110a to
extender housing 120. For example, projections 112a may be received
in openings 124 of extender housing 120. Extender modules 300 are
shown protruding from front housing 110a. Extender modules 300 may
be mounted to signal conductors of wafers 130 to form mating array
134a. Engagement of the projections 112a into openings 124 may be
achieved by applying a force that exceeds the mating force required
to press connectors 102a and 102b together for mating or to
separate those connectors upon unmating. Accordingly, extender
housing 120 may be fixed to front housing 110a during operation of
the connectors 102a and 102b.
[0096] Apertures 126 of extender housing 120 are sized to allow
mating ends of extender modules 300 to extend therethrough. Mating
ends of the signal and ground conductors of the extender modules
300 may then be exposed within a cavity serving as a mating
interface area bounded by walls of extender housing 120. The
opposite ends of the signal and ground conductors within the
extender modules 300 may be electrically coupled to corresponding
signal and ground conductors within wafers 130a. In this way,
connections between signal and ground conductors within wafers 130a
and connector 102b inserted into the mating interface area.
[0097] Extender housing 120 may be formed using a dielectric such
as plastic, for example in one or more molding processes. In the
illustrated embodiment, extender housing 120 includes grooves 122.
Grooves 122 are configured to receive projections 112b (FIG. 6) of
front housing 110b of second connector 102b. Sliding of projections
112b in grooves 122 may aid in aligning mating array 134a of first
electrical connector 102a with mating array 134b of second
electrical connector 102b before sliding the two connectors into a
mated configuration.
[0098] FIG. 5 is a perspective view of electrical connector 102a of
FIG. 1 with a single extender module 300. In the illustrated
embodiment, all extender modules 300 but one are removed so as to
show apertures 114a of front housing 110a through which extender
modules 300 extend. For example, apertures 114a are sized to expose
mating ends of the signal conductors of wafers 130, and to allow a
tail end of extender module 300 to be inserted into aperture 114a
to engage with conductive elements within wafers 130b.
[0099] FIG. 6 is a partially exploded view of second electrical
connector 102b of FIG. 1. Here, front housing 110b is shown
separated from wafers 130b. As shown in FIG. 6, wafers 130b of
second electrical connector 102b are each formed from multiple
connector modules 200. In the embodiment illustrated, there are
eight connector modules per wafer. Mating ends 202 of connector
modules 200 extend from wafer housing 132b to form mating end array
134b. When front housing 110b is attached to wafers 130b, mating
end array 134b extends into front housing 110b. The mating ends 202
are accessible through respective apertures 114b.
[0100] Contact tails 206 extend from wafer housing 132b in a
direction perpendicular to the direction in which mating ends 202
extend, so as to form contact tail array 136b. Connector modules
200 also include electromagnetic shielding 210 to provide isolation
for electrical signals carried by signal pairs of adjacent
connector modules 200. In the illustrated embodiment, that
shielding also has structures that form mating contact portions a
the mating ends 202 and structures that form contact tails that are
within contact tail array 136b. The electromagnetic shielding may
be formed from electrically conductive material, such as a sheet of
metal bent and formed into the illustrated shape so as to form
electrically conductive shielding.
[0101] Also shown in FIG. 6 of wafers 130b and retaining members
180. Retaining members 180 may be stamped of metal or formed of
other suitable material. Retaining members 180 may be configured to
secure multiple wafers 130b together, as described further herein
including with reference to FIGS. 9A-9C.
[0102] A mechanism may be provided to secure front housing 110b to
wafers 130b. In the illustrated embodiment, projecting tabs 150 are
sized and positioned to extend into openings 116b of front housing
110b to secure front housing 110b to wafers 130b. The force
required to insert and remove projecting tabs 150 from openings
116b may exceed the mating and/or unmating force of connectors 102a
and 102b.
[0103] It should be appreciated that in the above-described
embodiment, first and second electrical connectors 102a and 102b
include portions that may have the same construction in both
connectors. FIGS. 7-9C show in more detail portions of connectors
102a and 102b that may be the same for both first and second
electrical connectors 102a and 102b. Description of FIGS. 7-9C
refers to a generic electrical connector 102, which may apply in
some embodiments to first or second electrical connectors 102a and
102b.
[0104] FIG. 7 is a partially exploded view of electrical connector
102 with compliant shield 170, and without a front housing. The
inventors have recognized and appreciated that pairs of contact
tails 206 and/or electromagnetic shielding tails 220 passing
through compliant shield 170 may improve signal integrity in
electrical connector 102.
[0105] Pairs of contact tails 206 of contact tail array 136 may
extend through compliant shield 170. Compliant shield 170 may
include lossy and/or conductive portions and may also include
insulative portions. Contact tails 206 may pass through openings or
insulative portions of compliant shield 170, and may be insulated
from lossy or conductive portions. Ground conductors within
connector 102 may be electrically coupled to the lossy or
conductive portions, such as by electromagnetic shielding tails 220
passing through or pressing against lossy or conductive
portions.
[0106] In some embodiments, the conductive portions may be
compliant such that their thickness may be reduced when pressed
between connector 102 and a printed circuit board when connector
102 is mounted to the printed circuit board. Compliance may result
from the material used, and may result, for example, from an
elastomer filled with conductive particles or a conductive foam.
Such materials may lose volume when a force is exerted upon them or
may be displaced so as to exhibit compliance. The conductive and/or
lossy portions may be, for example, a conductive elastomer, such as
a silicone elastomer filled with conductive particles such as
particles of silver, gold, copper, nickel, aluminum, nickel coated
graphite, or combinations or alloys thereof. Alternatively or
additionally, such a material may be a conductive open-cell foam,
such as a polyethylene foam plated with copper and nickel.
[0107] If insulative portions are present, they may also be
compliant. Alternatively or additionally, the compliant material
may be thicker than the insulative portions of compliant shield 170
such that the compliant material may extend from the mounting
interface of connector 102 to the surface of a printed circuit
board to which connector 102 is mounted.
[0108] Compliant material may be positioned to align with pads on a
surface of a printed circuit board to which pairs of contact tails
206 of contact tail array 136 are to be attached to or inserted
through. Those pads may be connected to ground structures within
the printed circuit board such that, when electrical connector 102
is attached to the printed circuit board, the compliant material
makes contact with the ground pads on the surface of the printed
circuit board.
[0109] The conductive or lossy portions of compliant shield 170 may
be positioned to make electrical connection to electromagnetic
shielding 210 of connector modules 200. Such connections may be
formed, for example, by electromagnetic shielding tails 220 passing
through and contacting the lossy or conductive portions.
Alternatively or additionally, in embodiments in which the lossy or
conductive portions are compliant, those portions may be positioned
to press against the electromagnetic shielding tails 220 or other
structures extending from the electromagnetic shielding when
electrical connector 102 is attached to a printed circuit
board.
[0110] Insulative portions 176 may be organized into rows along a
row direction 172 and a column direction 174. When pairs of contact
tails 206 of contact tail array 136 extend through insulative
portions 176, row direction 172 of compliant shield 170 may
substantially align with contact tail row direction 146, and column
direction 174 of compliant shield 170 may substantially align with
contact tail column direction 144.
[0111] In the illustrated embodiment, conductive members 178 join
insulative portions 176 and are positioned between rows of contact
tail array 136. In this position, they may contact electromagnetic
shielding tails 220, as a result of being pressed against the tails
when compressed or as a result of shielding tails 220 passing
through conductive members 178.
[0112] FIG. 8 is a plan view of a portion 190 of substrate 104e,
illustrating a portion of a connector footprint to which connector
102 may be mounted. Here, a 4.times.4 grid of mounting locations,
of which mounting locations 194a and 194b are numbered, is shown.
Each mounting location can accommodate contact tails from a pair of
signal conductors and electromagnetic shielding tails 220 from
electromagnetic shielding around the pair. Here four such
electromagnetic shielding tails 220 are shown per pair.
[0113] Mounting locations 194a and 194b each include conductive
signal vias 196 and conductive ground vias 198. Conductive signal
vias 196 and conductive ground vias 198 are configured to receive
contact tails and/or electromagnetic shielding tails of an
electrical connector. For example, conductive signal vias 196 and
ground vias 198 may be formed as conductively plated holes into
which press fit tails are inserted. Alternatively, the signal
contact tails and/or electromagnetic shielding tails may be
soldered to pads on top of conductive signal vias 196 and/or
conductive ground vias 198.
[0114] Substrate 104e is implemented as a multi-layer printed
circuit board in the illustrated embodiment. FIG. 8 illustrates a
portion of an inner layer of the printed circuit board in which
traces are visible. Only two traces are illustrated, but it should
be appreciated that a pair of traces may be connected for each pair
of signal conductors. Those traces may be on the layer illustrated
or on another layer of the printed circuit board. Other layers may
also contain constructive structures serving as ground planes. The
shielding tails 220 may be connected to the ground planes.
[0115] Shown in phantom are ground pads 820, such as might be
formed on a surface of the printed circuit board. Ground pads 820
may be connected to one or more of the ground planes within the
printed circuit board. In the illustrated embodiment, ground pads
820 are positioned to align with conductive members 178 such that,
when connector 102 is mounted to the printed circuit board, a
conducting path is provided between electromagnetic shielding
within connector 102 and ground structures within the printed
circuit board.
[0116] In the embodiment illustrated, mounting locations are spaced
to leave routing channels, of which routing channels 192a and 192b
are numbered. Routing channels 192a and 192b accommodate traces
that can route signals from the vias, which are in turn connected
to contact tails of the connector, to other locations of the
printed circuit board.
[0117] In some embodiments, conductive signal vias 196 and/or
conductive shield vias have an unplated hole diameter of less than
or equal to 20 mils. In some embodiments, conductive signal vias
196 and/or conductive ground vias 198 have an unplated hole
diameter of less than or equal to 10 mils. The mounting locations
may then be spaced in an array with a center to center separation
in the column direction less than or equal to 2.5 mm and a center
to center separation in the row direction of less than or equal to
2.5 mm. With this spacing, there is room for routing channels
between the vias, including routing channels 192a in the column
direction and routing channels 192b in the row direction. Having
routing channels in both the row and column direction can be
advantageous, as it can reduce the number of layers in a printed
circuit board required to route traces to all of the signal vias in
a connector footprint in comparison to a printed circuit board in
which routing channels are available in only one direction. As
cost, size and weight all increase with increased layer count,
reducing the number of layers offers many advantages.
[0118] In some embodiments, conductive signal vias 196 of adjacent
mounting locations 194a and 194b are configured to receive adjacent
pairs of contact tails spaced a distance less than or equal to 5 mm
along line 146e. In some embodiments, conductive signal vias 196 of
adjacent mounting locations 194a and 194b are configured to receive
adjacent pairs of contact tails of an electrical connector, wafer
and/or connector module spaced a distance less than or equal to 4
mm from center to center along line 146e. In some embodiments,
conductive signal vias 196 of adjacent mounting locations 194a and
194b are configured to receive adjacent pairs of contact tails of
an electrical connector, wafer and/or connector module spaced a
distance less than or equal to 2.4 mm along line 146e. In a
perpendicular direction, adjacent mounting locations may be spaced
less than 8 mm, or less than 5 mm from center to center along line
144e, or less than 4 mm or less than or equal to 2.4 mm, in some
embodiments.
[0119] Routing channels in both the row and column direction,
despite a compact array of mounting locations, can be achieved by
implementing each of the mounting locations in a relatively compact
area. That compactness of the each mounting location may depend on
the separation between the signal conductors of a pair and the
separation between the signal conductors and the electromagnetic
shield surrounding them within a connector module 300.
[0120] The inventors have recognized and appreciated that these
dimensions can be made smaller by including superelastic materials
in electrical connectors. Superelastic materials may be
characterized by the amount of strain required for those materials
to yield, with superelastic materials tolerating a higher strain
before yielding. Additionally, the shape of the stress-strain curve
for a superelastic material includes a "superelastic" region.
[0121] Superelastic materials may include shape memory materials
that undergo a reversible martensitic phase transformation when a
suitable mechanical driving force is applied. The phase
transformation may be a diffusionless solid-solid phase
transformation which has an associated shape change; the shape
change allows superelastic materials to accommodate relatively
large strains compared to conventional (i.e. non-superelastic)
materials, and therefore superelastic materials often exhibit a
much larger elastic limit than traditional materials. The elastic
limit is herein defined as the maximum strain to which a material
may be reversibly deformed without yielding. Whereas conventional
conductors typically exhibit elastic limits of up to 1%,
superelastic conductive materials may have elastic limits of up to
7% or 8%. As a result, superelastic conductive materials can be
made smaller without sacrificing the ability to tolerate sizeable
strains. Moreover, some superelastic conductive materials may be
returned to their original form, even when strained beyond their
elastic limits, when exposed to a transition temperature specific
to the material. In contrast, conventional conductors are usually
permanently deformed once strained beyond their elastic limit.
[0122] Such materials may enable signal conductors that are small,
yet provide robust structures. Such materials facilitate decreasing
the width of electrical conductors of the electrical connectors,
which can lead to decreasing spacing between the electrical
conductors and electromagnetic shielding of the electrical
connectors in connector modules 300. Superelastic members, for
example, may have a diameter (or effective diameter as a result of
having a cross sectional area that equals the area of a circle of
that diameter) between and 20 mils in some embodiments, such as
between 8 and 14 mils, or in some embodiments between 5 and 8 mils,
or in any subrange of the range between 5 and 14 mils.
[0123] In addition to enabling routing channels in the row and
column directions, more compact connector modules may have
undesired resonant modes at high frequencies, which may be outside
the desired operational frequency range of the electrical
connector. There may be a corresponding reduction of the undesired
resonant frequency modes in the operational frequency range of the
electrical connector, which provides increased signal integrity for
signals carried by the connector modules.
[0124] In some embodiments, contact tails of contact tail array 136
and/or mating ends of mating end array 134 may include superelastic
(or pseudoelastic) material. Depending on the particular
embodiment, the superelastic material may have a suitable intrinsic
conductivity or may be made suitably conductive by coating or
attachment to a conductive material. For example, a suitable
conductivity may be in the range of about 1.5 .mu..OMEGA.cm to
about 200 .mu..OMEGA.cm. Examples of superelastic materials which
may have a suitable intrinsic conductivity include, but are not
limited to, metal alloys such as copper-aluminum-nickel,
copper-aluminum-zinc, copper-aluminum-manganese-nickel,
nickel-titanium (e.g. Nitinol), and nickel-titanium-copper.
Additional examples of metal alloys which may be suitable include
Ag--Cd (approximately 44-49 at % Cd), Au--Cd (approximately 46.5-50
at % Cd), Cu--Al--Ni (approximately 14-14.5 wt %, approximately
3-4.5 wt % Ni), Cu--Au--Zn (approximately 23-28 at % Au,
approximately 45-47 at % Zn), Cu--Sn (approximately 15 at % Sn),
Cu--Zn (approximately 38.5-41.5 wt % Zn), Cu--Zn--X (X=Si, Sn, Al,
Ga, approximately 1-5 at % X), Ni--Al (approximately 36-38 at %
Al), Ti--Ni (approximately 49-51 at % Ni), Fe--Pt (approximately 25
at % Pt), and Fe--Pd (approximately 30 at % Pd).
[0125] In some embodiments, a particular superelastic material may
be chosen for its mechanical response, rather than its electronic
properties, and may not have a suitable intrinsic conductivity. In
such embodiments, the superelastic material may be coated with a
more conductive metal, such as silver, to improve the conductivity.
For example, a coating may be applied with a chemical vapor
deposition (CVD) process, a physical vapor deposition (PVD)
process, or any other suitable coating process, as the disclosure
is not so limited. Coated superelastic materials also may be
particularly beneficial in high frequency applications in which
most of the electrical conduction occurs near the surface of
conductors.
[0126] In some embodiments, a connector element including a
superelastic material may be formed by attaching a superelastic
material to a conventional material which may have a higher
conductivity than the superelastic material. For example, a
superelastic material may be employed only in a portion of the
connector element which may be subjected to large deformations, and
other portions of the connector which do not deform significantly
during operation of the connector may be made from a conventional
(high conductivity) material.
[0127] The inventors have recognized and appreciated that
implementing portions of an electrical connector using superelastic
conductive materials enables smaller structures that are
nonetheless sufficiently robust to withstand the operational
requirements of an electrical connector, and therefore, may
facilitate higher signal conductor density within the portions made
of superelastic material. This closer spacing may be carried
through the interconnection system. For example, a mounting
footprint for receiving electrical connector 102 on a substrate may
be adapted for receiving high density contact tail array 136, as
described above with reference to FIG. 8.
[0128] Spacing between conductive signal vias 196 and/or conductive
ground vias 198 on substrate 104e may be adapted to match the
spacing of pairs of contact tails 206 of contact tail array 136
and/or electromagnetic shielding tails 220 of electrical connector
102. Accordingly, closer spacing between signal conductors and/or
smaller spacing between signal conductors and ground conductors
will yield a more compact footprint. Alternatively or additionally,
more space will be available for routing channels.
[0129] In some embodiments, contact tails of electrical connector
102 may be implemented with superconductive elastic materials,
which may enable smaller vias and closer spacing between adjacent
pairs than for conventional contact tails. In some embodiments,
conductive signal vias 196 of adjacent mounting locations 194a and
194b may be spaced on a 2.4 mm by 2.4 mm grid in some
embodiments.
[0130] Such close spacing may be achieved, by thin contact tails,
such as may be implemented with superelastic wires of a diameter
less than 10 mils, for example. In some embodiments, contact tails
of connectors described herein may be configured to be inserted
into plated holes formed with an unplated diameter of less than or
equal to 20 mils. In some embodiments, the contact tails may be
configured to be inserted into vias drilled with an unplated
diameter of less than or equal to 10 mils. In some embodiments, the
contact tails may each have a width between 6 and 20 mils. In some
embodiments, the contact tails may each have a width between 6 and
10 mils, or between 8 and 10 mils in other embodiments.
[0131] FIGS. 9A to 16C provide additional detail of components of
connector 102. FIG. 9A illustrates wafers 130, and FIGS. 9B-9C
illustrate retaining members 180 of electrical connector 102. In
the illustrated embodiment of FIG. 9A, wafers 130 are positioned
along contact tail row direction 146, and retaining tabs 152 of
wafer housings 132 are engaged with retaining members 180.
Retaining members 180 are configured to secure wafers 130 to one
another. In FIGS. 9B-9C, retaining members 180 include slots 182
for receiving retaining tabs 152 of wafers 130. Retaining members
180 may be stamped from metal, but may alternatively be formed of a
dielectric material such as plastic.
[0132] FIG. 10A is a perspective view of wafer 130 of electrical
connector 102. In the illustrated embodiment, wafer housing 132 is
formed from two housing members 133a and 133b. FIG. 10B is a
perspective view of wafer 130 with a wafer housing member 133a cut
away. As shown in FIGS. 10A and 10B, wafer 130 includes connector
modules 200 between two wafer housing members 133a and 133b. In the
illustrated embodiment, wafer housing members 133a and 133b hold
connector modules 200 in wafer 130.
[0133] Wafer housing members 133a and 133b include projections 154,
and holes 156 configured to receive projections 154, so as to hold
wafer housing members 133a and 133b together. In some embodiments,
wafer housing members 133a and 133b may be formed from or include a
lossy conductive material such as conductively plated plastic, or
an insulative material. The inventors have recognized and
appreciated that implementing wafer housing members 133a and 133b
using lossy conductive material provides damping for undesired
resonant modes in and between connector modules 200, thereby
improving signal integrity of signals carried by electrical
connector 102.
[0134] Any suitable lossy material may be used for these and other
structures that are "lossy." Materials that conduct, but with some
loss, or material which by another physical mechanism absorbs
electromagnetic energy over the frequency range of interest are
referred to herein generally as "lossy" materials. Electrically
lossy materials can be formed from lossy dielectric and/or poorly
conductive and/or lossy magnetic materials. Magnetically lossy
material can be formed, for example, from materials traditionally
regarded as ferromagnetic materials, such as those that have a
magnetic loss tangent greater than approximately 0.05 in the
frequency range of interest. The "magnetic loss tangent" is the
ratio of the imaginary part to the real part of the complex
electrical permeability of the material. Practical lossy magnetic
materials or mixtures containing lossy magnetic materials may also
exhibit useful amounts of dielectric loss or conductive loss
effects over portions of the frequency range of interest.
Electrically lossy material can be formed from material
traditionally regarded as dielectric materials, such as those that
have an electric loss tangent greater than approximately 0.05 in
the frequency range of interest. The "electric loss tangent" is the
ratio of the imaginary part to the real part of the complex
electrical permittivity of the material. Electrically lossy
materials can also be formed from materials that are generally
thought of as conductors, but are either relatively poor conductors
over the frequency range of interest, contain conductive particles
or regions that are sufficiently dispersed that they do not provide
high conductivity or otherwise are prepared with properties that
lead to a relatively weak bulk conductivity compared to a good
conductor such as copper over the frequency range of interest.
[0135] Electrically lossy materials typically have a bulk
conductivity of about 1 Siemen/meter to about 10,000 Siemens/meter
and preferably about 1 Siemen/meter to about 5,000 Siemens/meter.
In some embodiments material with a bulk conductivity of between
about 10 Siemens/meter and about 200 Siemens/meter may be used. As
a specific example, material with a conductivity of about 50
Siemens/meter may be used. However, it should be appreciated that
the conductivity of the material may be selected empirically or
through electrical simulation using known simulation tools to
determine a suitable conductivity that provides a suitably low
crosstalk with a suitably low signal path attenuation or insertion
loss.
[0136] Electrically lossy materials may be partially conductive
materials, such as those that have a surface resistivity between 1
.OMEGA./square and 100,000 .OMEGA./square. In some embodiments, the
electrically lossy material has a surface resistivity between 10
.OMEGA./square and 1000 .OMEGA./square. As a specific example, the
material may have a surface resistivity of between about 20
.OMEGA./square and 80 .OMEGA./square.
[0137] In some embodiments, electrically lossy material is formed
by adding to a binder a filler that contains conductive particles.
In such an embodiment, a lossy member may be formed by molding or
otherwise shaping the binder with filler into a desired form.
Examples of conductive particles that may be used as a filler to
form an electrically lossy material include carbon or graphite
formed as fibers, flakes, nanoparticles, or other types of
particles. Metal in the form of powder, flakes, fibers or other
particles may also be used to provide suitable electrically lossy
properties. Alternatively, combinations of fillers may be used. For
example, metal plated carbon particles may be used. Silver and
nickel are suitable metal plating for fibers. Coated particles may
be used alone or in combination with other fillers, such as carbon
flake. The binder or matrix may be any material that will set,
cure, or can otherwise be used to position the filler material. In
some embodiments, the binder may be a thermoplastic material
traditionally used in the manufacture of electrical connectors to
facilitate the molding of the electrically lossy material into the
desired shapes and locations as part of the manufacture of the
electrical connector. Examples of such materials include liquid
crystal polymer (LCP) and nylon. However, many alternative forms of
binder materials may be used. Curable materials, such as epoxies,
may serve as a binder. Alternatively, materials such as
thermosetting resins or adhesives may be used.
[0138] Also, while the above described binder materials may be used
to create an electrically lossy material by forming a binder around
conducting particle fillers, the invention is not so limited. For
example, conducting particles may be impregnated into a formed
matrix material or may be coated onto a formed matrix material,
such as by applying a conductive coating to a plastic component or
a metal component. As used herein, the term "binder" encompasses a
material that encapsulates the filler, is impregnated with the
filler or otherwise serves as a substrate to hold the filler.
[0139] Preferably, the fillers will be present in a sufficient
volume percentage to allow conducting paths to be created from
particle to particle. For example, when metal fiber is used, the
fiber may be present in about 3% to 40% by volume. The amount of
filler may impact the conducting properties of the material.
[0140] Filled materials may be purchased commercially, such as
materials sold under the trade name Celestran.RTM. by Celanese
Corporation which can be filled with carbon fibers or stainless
steel filaments. A lossy material, such as lossy conductive carbon
filled adhesive preform, such as those sold by Techfilm of
Billerica, Mass., US may also be used. This preform can include an
epoxy binder filled with carbon fibers and/or other carbon
particles. The binder surrounds carbon particles, which act as a
reinforcement for the preform. Such a preform may be inserted in a
connector wafer to form all or part of the housing. In some
embodiments, the preform may adhere through the adhesive in the
preform, which may be cured in a heat treating process. In some
embodiments, the adhesive may take the form of a separate
conductive or non-conductive adhesive layer. In some embodiments,
the adhesive in the preform alternatively or additionally may be
used to secure one or more conductive elements, such as foil
strips, to the lossy material.
[0141] Various forms of reinforcing fiber, in woven or non-woven
form, coated or non-coated may be used. Non-woven carbon fiber is
one suitable material. Other suitable materials, such as custom
blends as sold by RTP Company, can be employed, as the present
invention is not limited in this respect.
[0142] In some embodiments, a lossy portion may be manufactured by
stamping a preform or sheet of lossy material. For example, a lossy
portion may be formed by stamping a preform as described above with
an appropriate pattern of openings. However, other materials may be
used instead of or in addition to such a preform. A sheet of
ferromagnetic material, for example, may be used.
[0143] However, lossy portions also may be formed in other ways. In
some embodiments, a lossy portion may be formed by interleaving
layers of lossy and conductive material such as metal foil. These
layers may be rigidly attached to one another, such as through the
use of epoxy or other adhesive, or may be held together in any
other suitable way. The layers may be of the desired shape before
being secured to one another or may be stamped or otherwise shaped
after they are held together. As a further alternative, lossy
portions may be formed by plating plastic or other insulative
material with a lossy coating, such as a diffuse metal coating.
[0144] As shown in FIG. 10B, connector modules 200 are aligned
along mating column direction 140. As shown in FIG. 10B, connector
modules 200 include mating ends 202 and mounting ends where contact
tails 206 of signal conductors within the module are exposed. The
mating ends and mounting ends of modules 200 are connected by
intermediate portions 204. Connector modules 200 also include
electromagnetic shielding 210, having electromagnetic shielding
tails 212 and electromagnetic shielding mating ends 212, that are
at the mounting end and mating end of the module, respectively.
[0145] In the illustrated embodiment, mating ends of signal
conductors of each connector module are separated along parallel
lines 138 at mating ends 202, which make a 45 degree angle relative
to mating column direction 140.
[0146] In the illustrated embodiment, contact tails 206 of signal
conductors within the connector modules are positioned in a column
along contact tail column direction 144, and pairs of contact tails
206 are also separated along contact tail column direction 144. As
shown, contact tail column direction 144 is orthogonal to mating
column direction 140. It should be appreciated, however, the mating
end and mounting end may have any desired relative orientation.
Contact tails 206 may be either edge or broadside coupled, in
accordance with various embodiments.
[0147] FIG. 11 is a plan view of housing member 133b and one
connector module 200 of wafer 130. As shown in FIG. 11, wafer
housing member 133b includes grooves 160 shaped to receive
connector modules 200. Housing member 133a similarly may include
grooves that cooperate with grooves 160 to form channels in which
connector modules 200 are disposed.
[0148] Grooves 160 include first notches 162 and second notches
164, each shaped to receive a projection from connector modules
200, such as a projection 232. Such notches and projections may
provide mechanical integrity to wafer 130 such that modules 200 do
not rotate when connector 102 is pressed onto a printed circuit
board, for example.
[0149] FIGS. 12A-12C illustrate a side view, a perspective view,
and an alternate perspective view of a representative connector
module 200, respectively. As shown in FIG. 10B, a wafer may include
a column of connector modules 200. Each of the connector modules
may be in a separate row at the mating and mounting interface of
the connector. In a right angle connector, the modules in each row
may have a different length intermediate portion 204. The mating
ends and mounting ends may be the same, in some embodiments.
[0150] As shown in FIGS. 12A-12C, electromagnetic shielding members
210a and 210b are disposed around inner insulative member 230.
First and second retaining members 222 of electromagnetic shielding
members 210a and 210b retain first shielding member 210a to second
shielding member 210b enclosing inner insulative member 230.
[0151] In the illustrated embodiment, electromagnetic shielding
members 210 fully cover connector module 200 on two sides, with a
gap 218 on the remaining two sides such that only partial covering
is provided on those sides. Inner insulative member 230 is exposed
through gap 218. However, in some embodiments, electromagnetic
shielding members 210 may fully cover the insulative member 230 on
4 sides. Gaps 218 may be relatively narrow, so as not to allow any
significant amount of electromagnetic energy to pass through the
gap. The gaps, for example, may be less than one half or, in some
embodiments, less than one quarter of a wavelength of the highest
frequency in the intended operating range of the connector. Signal
conductors within connector module 200 are described herein
including with reference to FIGS. 16A-16C. Electromagnetic
shielding members 210 may be electrically conductive shielding. For
example, electromagnetic shielding members 210 may be stamped from
a sheet of metal.
[0152] FIGS. 12A-12C indicate first transition region 208a and
second transition region 208b of connector module 200. In first
transition region 208a, mating ends 202 are connected to
intermediate portions 204. In second transition region 208b,
intermediate portions 204 are connected to contact tails 206.
[0153] Electromagnetic shielding members 210a and 210b include
electromagnetic shielding mating ends 212, at mating ends 202, and
electromagnetic shielding tails 220, which extend from module 200
parallel to and alongside contact tails 206 of signal conductors
within module 200. Electromagnetic shielding mating ends 212
surround the mating ends of the signal conductors.
[0154] Electromagnetic shielding mating ends 212 are embossed with
outwardly projecting portions 214 in first transition region 208a
and with inwardly projecting portions 216 at the mating ends 202.
Accordingly, outwardly projecting portions 214 are disposed between
intermediate portions 204 and inwardly projecting portions 216.
Embossing electromagnetic shielding mating ends 212 with outwardly
projecting portions 214 offsets changes in impedance along a length
of connector modules 200 associated with changes in shape of
connector module 200 in the transition region. An impedance along
signal paths through connector module 200 may be between 90 and 100
ohms at frequencies between 45-50 GHz, for example.
[0155] Embossing electromagnetic shielding mating ends 212 with
inwardly projecting portions 216 provides a more constant impedance
between an operating state in which connector module 200 is pressed
firmly against a mating connector and an operating stated in which
connector module 200 is partially demated such that there is a
separation between connector module 200 and the mating connector
but the connectors are sufficiently close that the signal
conductors in those connectors mate. In some embodiments, an
impedance change between fully mated and partially demated
configurations of mating ends 202 is less than 5 ohms at operating
frequencies of the connector, such as in a range of 45-50 GHz.
[0156] FIGS. 13A-13C are a side view, a perspective view, and an
alternative side view, respectively, of connector module 200 with
electromagnetic shielding members 210a and 210b cut away. As shown
in FIGS. 13A-13C, outer insulative members 280a and 280b are
disposed on opposite sides of inner insulative member 230. Outer
insulative members 280a and 280b may be formed using a dielectric
material such as plastic. Projection 232 of inner insulative member
230 is disposed closer to contact tails 206 than to mating ends 202
and extends in a direction opposite the direction along which
contact tails 206 extend.
[0157] Mating ends 202 of signal conductors within connector module
200 include compliant receptacles 270a and 270b, each having mating
arms 272a and 272b. In the illustrated embodiment, compliant
receptacles 270a and 270b are configured to receive and make
contact with a mating portion of a signal conductor of a mating
connector between mating arms 272a and 272b.
[0158] Also shown in FIGS. 13A-13C, insulative portions of
connector module 200 may insulate receptacles 270a and 270b from
each other. Those insulative portions may also position receptacles
270a and 270b and provide apertures through which mating portions
of a mating connector may enter receptacles 270a and 270b. Those
insulative portions may be formed as part of insulative member 230.
In the embodiment illustrated, inner insulative member 230 has an
extended portion 234, which includes arms 236a and 236b and
apertures 238a and 238b. Extended portion 234 extends beyond
compliant receptacles 270a and 270b in a direction along which
mating ends 202 are elongated. Arms 236a and 236b are spaced
farther apart than are mating ends 202. Apertures 238a and 238b may
be configured to receive wires therethrough such that the wires
extend into compliant receptacles 270a and 270b. For example, gaps
between arms 272a and 272b of compliant receptacles 270a and 270b
are aligned with apertures 238a and 238b.
[0159] FIGS. 14A-14C are a side view, a perspective view, and an
alternative side view, respectively, of connector module 200 with
electromagnetic shielding members 210a and 210b as well as outer
insulative members 280a and 280b cut away. As shown in FIGS.
14A-14C, connector module 200 includes signal conductors 260, here
shown as signal conductors 260a and 260b implemented as a
differential pair. When connector module 200 is assembled, signal
conductor 260a may be disposed between outer insulative member 280a
and inner insulative member 230, and signal conductor 260b may be
disposed between outer insulative member 280b and inner insulative
member 230.
[0160] One or more of inner insulative member 230 and outer
insulative members 280a and 280b may include features to hold the
insulative components together, thereby firmly positioning the
signal conductors 260 within in the insulative structure. In the
illustrated embodiment, first and second retaining members 240 and
242 of inner insulative member 230 may extend into openings in
outer insulative members 280a and 280b. In the illustrated
embodiment, first retaining members 240 are disposed adjacent
mating ends 202 and extend in a direction perpendicular to the
direction along which mating ends 202 extend. Second retaining
members 242 are disposed adjacent contact tails 206 and extend in a
direction perpendicular to the direction along which contact tails
206 extend.
[0161] Intermediate portions of signal conductors 260a and 260b are
on opposite sides of inner insulative member 230. In the
illustrated embodiments, signal conductors 260a and 260b are each
stamped from a sheet of metal and then bent into the desired shape.
The intermediate portions are flat with a thickness equaling the
thickness of the sheet of metal. As a result, the intermediate
portions have opposing broadsides, joined by edges that are thinner
than the broad sides. In the embodiment, the intermediate portions
are aligned broadside to broadside, providing for broadside
coupling within the module 200.
[0162] In FIGS. 14A-14C, signal conductors 260 include mating ends
262, intermediate portions 264, and contact tails 266 located at
mating ends 202, intermediate portions 204, and contact tails 206
of connector module 200. As shown, mating ends 262 include
compliant receptacles 270a and 270b, and contact tails 266 include
eye of the needle press fit tails.
[0163] In the illustrated embodiment, the mating ends 262 and
contact tails 266 of the pair of signal conductors 260 are not
aligned broadside to broadside, as are the intermediate portions
264. Accordingly, the relative position of the signal conductors
260a and 260b of the pair changes between the intermediate portions
264 and each of the mating ends 262 and contact tails 266. The
relative positions change in transition regions 268a and 268b.
[0164] A first transition region 268a of signal conductors 260
connects mating ends 262 to intermediate portions 264. A second
transition region 268b connects contact tails 266 of signal
conductors 260 to intermediate portions 264. In each of these
transition regions 268a and 268b, the angular position about an
axis parallel to the longitudinal dimension of the signal
conductors 260a and 260b of the pair changes. The angular distance
between the signal conductors 260a and 260b may remain the same,
such as at 180 degrees. In the illustrated embodiment, the angular
position of the signal conductors 260a and 260b changes 45 degrees
within transition region 268a and 90 degrees within transition
region 268b so that, considered across the transition regions 268a
and 268b, there are angular twists to the pair.
[0165] Inner insulative member 230 may be shaped to accommodate a
pair of signal conductors with such transition regions. In the
illustrated embodiment, signal conductors 260 are disposed in
grooves 250 on opposite sides of inner insulative member 230.
Transition regions 268a and 268b of signal conductors 260 are
disposed within transition guides 252a and 252b of grooves 250.
Grooves 250 of inner insulative member 230 are described herein
including with reference to FIG. 15.
[0166] It should be appreciated that some embodiments do not
include second transition region 268b, such as in FIG. 23 where the
contact tails are shown aligned broadside to broadside.
[0167] FIG. 15 is a perspective view of inner insulative member 230
of connector module 200. As shown in FIG. 15, inner insulative
member 230 includes main body 244 and extended portion 234 joined
together by connecting portion 246. Inner insulative member 230 may
be formed using a dielectric material such as plastic and may be
formed by molding, for example. Opposing sides of main body 244
include grooves 250. Grooves 250 are shaped to receive signal
conductors 260 of connector module 200. In the illustrated
embodiment, grooves 250 include first and second transition guides
252a and 252b configured to conform to the signal conductors in
transition regions 268a and 268b. For example, transition guides
252a and 252b may be shaped to accommodate a transition of signal
conductors 260. Connecting portion 246 is disposed between extended
portion 234 and main body 244.
[0168] FIG. 16A-16C are a side view, a perspective view, and an
alternative side view of signal conductors 260a and 260b of
connector module 200 of FIG. 14A-C. As shown in FIGS. 16A-16C,
mating ends 262a and 262b extend in a first direction and contact
tails 266a and 266b extend in a second direction at a right angle
relative to the first direction. In the illustrated embodiment,
contact tails 266a and 266b are configured as press-fit ends. Thus,
contact tails 266a and 266b may be configured to compress upon
insertion into a hole, such as in a printed circuit board.
[0169] Here, each signal conductor 260a and 260b is configured to
carry a component of a differential signal. Signal conductors 260a
and 260b each may be formed as a single, integral conductive
element, which may be stamped from a metal sheet. However, in some
embodiments, signal conductors 260a and 260b each may be formed of
multiple conductive elements fused, welded, brazed or otherwise
joined together. For example, portions of signal conductors 260a
and 260b, such as contact tails 266a and 266b and mating ends 262a
and 262b, may be formed using superelastic conductive
materials.
[0170] As a result of transition region 268a, mating ends 262a and
262b are separated from each other along line 138, while
intermediate portions 264a and 264b adjacent mating ends 262a and
262b are separated along mating row direction 142. As illustrated,
for example in FIG. 7, connector 102 may be constructed such that
all of the modules 200 positioned in rows that extend in the row
direction 142. All of the modules may include similarly oriented
mating ends, such that, for each module, the mating ends of the
signal conductors will be separated from each other along a line
parallel to line 138.
[0171] A relative position of signal conductors 260a and 260b
varies along first transition region 268a such that at a first end
of first transition region 268a adjacent mating ends 262a and 262b,
signal conductors 260a and 260b are aligned along first parallel
line 138, and at a second end of first transition region 268a
adjacent intermediate portions 264a and 264b, signal conductors
260a and 260b are aligned along mating row direction 142. In the
illustrated example, first transition region 268a provides a 45
degree twist between line 138 and mating row direction 142. Within
first transition region 268a, signal conductor 260a extends away
from contact tail column direction 144, and signal conductor 260b
extends towards contact tail column direction 144.
[0172] Despite the variation of the relative position of the signal
conductors 260a and 260b across the transition region, the
inventors have recognized and appreciated that signal integrity of
the pair of signal conductors may be enhanced by configuring module
200 to maintain each of signal conductors 260a and 260b adjacent
the same respective shielding member 210a or 210b throughout the
transition region. Alternatively or additionally, the spacing
between the signal conductors 260a and 260b and the respective
shielding member 210a or 210b may be relatively constant over the
transition region. The separation between signal conductor and
shielding member, for example, may vary by no more than 30%, or 20%
or 10% in some embodiments.
[0173] Module 200 may include one or more features that provide
this relative positioning and spacing of signal conductors and
shielding members. As can be seen, for example from a comparison of
FIGS. 12A . . . 12C and FIGS. 16A . . . 16C, shielding member 210a
and 210b have a generally planar shape in the intermediate portions
204, which parallels the intermediate portions of 264 of a
respective signal conductor 260a or 260b. The shield mating ends
212 may be formed from the same sheet of metal as the intermediate
portions, with the shield mating ends 212 twisted with respect to
the intermediate portions 204. The twist of the shielding member
may have the same angle and/or same rate of angular twist as the
signal conductors, ensure that each signal conductor, ensuring that
the same shielding member is adjacent the same signal conductor
throughout the transition region.
[0174] Further, as can be seen in FIGS. 16A-16C, mating ends 262a
and 262b are formed by rolling conductive material of the sheet of
metal from which signal conductors 260 are formed into a generally
tubular configuration. That material is rolled towards the
centerline between mating ends 262a and 262b. Such a configuration
leaves a flat surface of the signal conductors facing outwards
toward the shield members, which may aid in keeping a constant
spacing between the signal conductors and the shield members, even
in the twist region.
[0175] It should be appreciated, that a spacing between signal
conductors 260a and 260b may be substantially constant in units of
distance. Alternatively, the spacing may provide a substantially
constant impedance. In such a scenario, for example, where the
signal conductors are wider, such as a result of being rolled into
tubes, the spacing relative to the shield may be adjusted to ensure
that the impedance of the signal conductors is substantially
constant. As shown in FIGS. 16A-16C, contact tails 266a and 266b
are separated along contact tail column direction 144, and
intermediate portions 264a and 264b adjacent contact tails 266a and
266b are separated along contact tail row direction 146. Thus,
contact tails 266a and 266b are separated along a first direction,
and intermediate portions 264a and 264b adjacent contact tails 266a
and 266b are separated along a second direction perpendicular to
the first direction. This difference in the direction in which
segments of the same conductors are separated is the result of
second transition region 268b. In the illustrated embodiment, the
signal conductors twist 90 degrees in second transition region 268b
such that there is a 90 degree difference between the contact tail
column direction 144 and second contact tail row direction 146. A
relative position of signal conductors 260a and 260b varies along
second transition region 268b such that at a first end of second
transition region 268b adjacent contact tails 266a and 266b, signal
conductors 260a and 260b are aligned along contact tail column
direction 144, and at a second end of second transition region 268b
adjacent intermediate portions 264a and 264b, signal conductors
260a and 260b are aligned along contact tail row direction 146.
[0176] As described above, extender modules 300 enable the mating
interface of electrical connector 102 to be adapted. In some
embodiments, such as is illustrated in FIG. 1, connectors, such as
connector 102, may be mated to each other by attaching extender
modules to one of the connectors. Extender modules 300 may be
mounted on connector modules 200 to provide a modified mating
interface for electrical connector 102. Accordingly, extender
modules 300 may be configured at one end for attachment to the
mating interface of a connector 102 and, at the other end, for
mating with a connector 102. In such a configuration, there may be
one extender module attached to each connector module 200.
[0177] FIG. 17A is perspective view of connector module 200 with an
extender module 300 attached. FIG. 17B is a perspective view of
connector module 200 and extender module 300, with electromagnetic
shielding members 210a and 210b cut away. FIG. 17C is a perspective
view of signal conductors 260 of connector module 200 and extender
module of FIG. 17C.
[0178] Extender module 300 includes mating portions 304a and 304b
at an end of extender module 300. Mating portions 304a and 304b
extend away from connector module 200. Here, the mating portions
304a and 304b are configured as round conductors that fit into
receptacles of a mating connector. In embodiments in which the
mating connector has receptacles, such as receptacles 270a and
270b, mating arms 272a and 272b will be sized to be deflected upon
insertion of mating portions 304a and 304b, and generate a contact
force. In some embodiments, the contact force may be between 25 and
45 gm. In some embodiments, contact force may be between 30 and 40
gm.
[0179] In FIGS. 17A-C, extender module 300 is attached to connector
module 200. The attachment between extender module 300 and
connector module 200 may be separable such that extender module 300
may be removed from connector module 200 and reattached multiple
times. However, in the embodiment illustrated, extender module 300
is configured to make a connection to connector module 200 that
remains throughout the useful life of the connector resulting from
the combination. Portions 306a and 306b of signal conductors 302 of
extender module 300 extend toward connector module 200 and are
configured to make such a connection.
[0180] In the illustrated embodiment, mating portions 304a and 304b
of signal conductors 302 of extender module 300 are located at
mating interface 314 of extender module 300. Second portions 306a
and 306b of signal conductors 302 of extender module 300 are
located at mounting interface 316 of extender module 300. Each of
mating portions 304a and 304b and second portions 306a and 306b
extend along a direction parallel to a direction in which extender
module 300 is elongated. Second portions 306a and 306b include
contact tails configured to extend through apertures 238a and 238b
of extended portion 234 of inner insulative member 230. When
mounted to connector module 200, second portions 306a and 306b are
positioned between mating arms 272a and 272b of each of compliant
receptacles 270a and 270b. In the illustrated embodiment, second
portions 306a and 306b terminate in press fit ends configured for
inserting between mating arms 272a and 272b. Mounting second
portions 306a and 306b of signal conductors 302 of extender module
300 to mating ends 262 of signal conductors 260 of connector module
200 may require at least 60 N of force.
[0181] In some embodiments, mating portions 304a and 304b and/or
second portions 306a and 306b may be formed of superelastic
conductive materials. Use of superelastic materials may enable
those components to have a small width while providing sufficient
robustness. For example, mating portions 304a and 304b may have an
effective diameter between 5 and 20 mils. Signal conductors with
superelastic mating portions may be formed entirely of superelastic
material. Alternatively, conductor may be formed in part from a
conventional metal, such as phosphor bronze, with a superelastic
component attached to it. For example, the superelastic wire may be
attached by tabs forming a mechanical connection or brazed to the
conventional metal member. In some embodiments, mating portions
304a and 304b and/or second portions 306a and 306b may include
superelastic wires having a width between 5 and 20 mils. In some
embodiments, mating portions 304a and 304b and/or second portions
306a and 306b may include superelastic wire having a width of less
than 12 mils.
[0182] Mating portions 304a and 304b of signal conductors 302 of
extender module 300 may be configured to mate with mating ends 262a
and 262b of signal conductors 260 of connector module 200. In the
illustrated embodiment, mating portions 304a and 304b terminate in
pins configured to extend through apertures 238a and 238b of
extended portion 234 and are sized to fit between arms 272a and
272b of compliant receptacles 270a and 270b. When formed using
superelastic materials, mating portions 304a and 304b may be spaced
apart a distance less than a distance the apertures of extended
portion 234 are spaced apart, such that mating portions 304a and
304b deform as they extend through the apertures and/or into mating
ends 262a and 262b, and reform when removed from the apertures
and/or mating ends 262a and 262b.
[0183] Use of small diameter wires may also support closer spacing
between signal pairs within the connector and also shielding
surrounding each pair that has a relatively small cross sectional
area, including at the mating interface of the connector, where the
electromagnetic shielding may have its largest cross sectional
area. The effective diameter of the signal conductors at the mating
interface is set by the outer dimensions of the arms 272a and 272b
of compliant receptacles 270a and 270b, as deflected by the
insertion of the mating portions 304a and 304b. Smaller diameter
mating portions 304a and 304b enables the outer dimensions of the
arms 272a and 272b, as deflected, to be smaller. That smaller
dimension for the signal conductors in turn leads to smaller
separation between the components at the mating interface,
including signal conductors and grounded electromagnetic shielding
surrounding the signal conductors to provide a desired impedance
for the signal conductors.
[0184] The cross-sectional area of the largest portion of an
electromagnetic shielding, for example, may be in the range of 3 to
5 mm.sup.2, with a largest dimension less than 4 mm, such as 3.8 mm
or less, or less than 3.5 or 3 mm in some embodiments. Such small
dimensions may establish a frequency for the lowest frequency
resonant mode supported by the enclosure formed by the
electromagnetic shielding that is outside the desired operating
range of the connector. Resonant frequencies outside the operating
range improve the integrity of signals passing through the
connection system.
[0185] A further advantage of connectors described herein is the
consistency of the mating interfaces provided. Regardless of
whether the connector is mated directly with another connector, or
with one or more extender modules forming the mating interface
therebetween, each mating interface may provide desirable impedance
characteristics. For instance, mating portions 304a and 304b of
signal conductors 302 of extender module 300 may provide the same
benefits of uniformity of impedance associated with mating portions
of a mating connector, even if mating portions 304a and 304b are
not fully seated within the mating ends of the mated connector,
such as compliant receptacles 270a and 270b of connector module
200. In some embodiments, an impedance change between mated and
demated configurations of mating ends 202 may be less than 5 ohms
at operating frequencies of the connector, such as in a range of
45-50 GHz.
[0186] FIGS. 18A-18C are a perspective view, a side view, and an
alternative side view of extender module 300. As shown in FIGS.
18A-18C, extender module 300 includes insulative member 330,
electromagnetic shielding members 310a and 310b, and a pair of
signal conductors that each has a mating portion and a portion for
attachment to a signal conductor within a connector extending from
insulative member 330.
[0187] In the illustrated embodiment, extender module 300 is
elongated in a straight line from mating portions 304a and 304b at
mating interface 314 to second portions 306 and 306b at mounting
interface 316. Mating portions 304a and 304b of signal conductors
302 are separated from each other along first line 320. Second
portions 306a and 306b of signal conductors 302 are similarly
separated from each other along a line, here second line 322
parallel to first line 320.
[0188] Additional details of the second portions 306a and 306b are
visible in FIGS. 18A-18C. As illustrated, those portions are press
fit tails having a shape that will compress when inserted into an
opening to assert a force against the sides of the opening. The
press-fit tail is illustrated as an "S" shaped or serpentine
cross-section. Press-fits of other shapes, such as an eye of the
needle press fit used to attach signal conductors to printed
circuit boards may alternatively be used on some or all of the
connector modules.
[0189] Insulative member 330 may be formed using a dielectric
material such as plastic, which may be insert molded or otherwise
formed around the signal conductors of the extender module.
Insulative member may be formed with structural features. For
example, insulative member 330 may include features to facilitate
attachment to or mating with signal modules. Projections 332a and
332b and projections 334a and 334b may be shaped to fit between
projecting portions 216 at mating ends 202 of a connector module
200. Alternatively or additionally, insulative member 330 may
include features to facilitate engagement to or positioning with
respect to a front housing 110 and/or an extender housing 120.
Wings 336a and 336b may provide this function. Wings 336a and 336b
are disposed between mating interface 314 and mounting interface
316, and extend in opposite directions parallel to lines 320 and
322. Wings 336a and 336b each have recessed portions 338a or 338b,
which are indented in a direction opposite a direction the
respective wing 336a or 336b extends.
[0190] Electromagnetic shielding members 310a and 310b may be
attached on opposite sides of extender module 300. Electromagnetic
shielding members 310a and 310b may include electrically conductive
shielding. For example, electromagnetic shielding members 310a and
310b may be stamped from a sheet of metal. Electromagnetic
shielding member 310a includes first attachment member 312a and
electromagnetic shielding member 310b includes second attachment
member 312b for engaging with first attachment member 312a to
attach electromagnetic shielding members 310a and 310b to one
another. In the illustrated embodiment, first attachment member
312a includes a hooked tab and second attachment member 312b
includes an opening for receiving the tab such that the hooked
portion of the tab is latched in the opening. First and second
attachment members 312a and 312b engage with one another at
recessed portions 338a and 338b of wings 336a and 336b.
[0191] Electromagnetic shielding members 310a and 310b may also
include features for mating with electromagnetic shielding members
within connector modules to which extender module 300 is mated or
attached. In the example of FIGS. 18A-18C, mating contact surfaces
are formed on portions of electromagnetic shielding members 310a
and 310b. Mating contact portions 350a, 350b, 352a and 352b are
formed at each distal end of shielding members 310a and 310b,
adjacent the mating or mounting interfaces. Mating contact portions
350a, 350b, 352a and 352b are here illustrated as a convex surface
formed in electromagnetic shielding members 310a and 310b. That
convex surface may be plated with gold or other material resistant
to oxidation to enhance electrical contact. Further, the distal
most portion of the electromagnetic shielding members 310a and
310b, beyond the mating contact portions, may be embedded within or
guarded by portions of insulative member 330 so as to preclude
stubbing or catching of electromagnetic shielding members 310a and
310b on structures with connector modules 200 upon insertion into a
mating end 262 of signal conductors 260 of connector module
200.
[0192] FIGS. 19A-19B are a side view and an alternate side view of
extender module 300, with electromagnetic shielding members 310a
and 310b cut away from the extender module so as to better
illustrate insulative member 330.
[0193] FIGS. 20A-20B are a side view and an alternative side view
of signal conductors 302a and 302b of extender module 300.
[0194] Signal conductors 302a and 302b may be stamped from a sheet
of metal. Alternatively, signal conductors 302a and 302b may be
formed using multiple conductive elements fused, welded, brazed or
otherwise joined together. For example, mating portions 304a and
304b and/or second portions 306a and 306b of signal conductors 302a
and 302b may be formed separately and then attached to one another.
Such an approach may enable mating portions 304a and 304b to be
readily formed with smooth surfaces and/or with different material
properties. In some embodiments mating portions 304a and 304b may
be formed of a superelastic conductive material. In some
embodiments, mating portions 304a and 304b include superelastic
wires having a diameter between 5 and 20 mils.
[0195] The construction techniques employed in making extender
modules 300 may also be used in forming modules of other
configurations. FIG. 21A illustrates a header connector 2120, such
as might be mounted to a printed circuit board formed with modules
2130 that may be formed using construction techniques as described
above in connection with extender modules 300. In this example,
header connector 2120 has a mating interface that is the same as
the mating interface of connector 102a. In the illustrated
embodiment, both have mating ends of pairs of signal conductors
aligned along parallel lines angled at 45 degrees relative to
column and/or row directions of the mating interface. Accordingly,
header connector 2120 may mate with a connector in the form of
connector 102b. The mounting interface 2124 of header connector
2120, however, is in a different orientation with respect to the
mating interface than the mounting interface of connector 102a.
Specifically, mounting interface 2124 is parallel to mating
interface 2122 rather than perpendicular to it. Header connector
2120 may be adapted for use in backplane, mid-board, mezzanine, and
other such configurations. For example, header connector 2120 may
be mounted to a backplane, a midplane or other substrate that is
perpendicular to a daughtercard or other printed circuit board to
which a right angle connector, such as connector 102b, is attached.
Alternatively, header connector 2120 may receive a mezzanine
connector having a same mating interface as connector 102b. The
mating ends of the mezzanine connector may face a first direction
and the contact tails of the mezzanine connector may face a
direction opposite the first direction. For example, the mezzanine
connector may be mounted to a printed circuit board that is
parallel to the substrate onto which header connector 2120 is
mounted.
[0196] In the embodiment illustrated in FIG. 21A, header connector
2120 has a housing 2126, which may be formed of an insulative
material such as molded plastic. However, some or all of housing
2126 may be formed of lossy or conductive material. The floor of
housing 2126, though which connector modules pass, for example, may
be formed of or include lossy material coupled to electromagnetic
shielding of connector modules 2130. As another example, housing
2126 may be die cast metal or plastic plated with metal.
[0197] Housing 2126 may have features that enable mating with a
connector. In the illustrated embodiment, housing 2126 has features
to enable mating with a connector 102b, the same as housing 120.
Accordingly, the portions of housing 2126 that provide a mating
interface are as described above in connection with housing 120 and
FIG. 2A. The mounting interface 2124 of housing 2126 is adapted for
mounting to a printed circuit board.
[0198] Such a connector may be formed by inserting connector
modules 2130 into housing 2126 in rows and columns. Each module may
have mating contact portions 2132a and 2132b, which may be shaped
like mating portions 304a and 304b, respectively. Mating contact
portions 2132a and 2132b may similarly be made of small diameter
superelastic wires.
[0199] FIG. 21B shows an exemplary connector module 2130 in greater
detail. As with extender module 300, portions of a pair of
conductive elements may be held within an insulative portion (not
numbered). Mating contact portions 2132a and 2132b, which may be
integral with the portions of the conductive elements within the
housing or separately formed and attached to those portions, extend
from a mating interface portion of connector module 2130.
[0200] Contact tails 2134a and 2134b may extend from a mounting
interface portion of the connector module 2130. Contact tails 2134a
and 2134b may be integral with the portions of the conductive
elements within the housing, and may be shaped like contact tails
206a and 206b (FIG. 17C).
[0201] Connector module 2130 may also have electromagnetic
shielding members on opposing sides, similar to electromagnetic
shielding members 310a and 310b. Electromagnetic shielding member
2140a is visible in the view of FIG. 21B. A complementary shielding
member (not visible) may be attached to the opposing side of
connector module 2130. The mating end of shielding member 2140a may
be shaped similarly to the mating ends of shielding members 310a
and 310b. For example, shielding member 2140a includes mating
contact portion 2144a, which may be shaped like mating contact
portion 350a.
[0202] The mounting ends of connector module 2130 may be shaped
like the mounting ends of connector modules 200. Accordingly, the
electromagnetic shielding members may include contact tails 2142a
and 2142b that are shaped and positioned with respect to contact
tails 2134a and 2134b in the same way that electromagnetic
shielding tails 220 are shaped and positioned with respect to
contact tails 206a and 206b.
[0203] In the embodiment illustrated in FIG. 21A, pairs of mating
contact portions 2132a and 2132b are separated from each other
along parallel lines that are at an approximately 45 degree angle
with respect to the row and/or column directions. Such a
configuration may be achieved by conductive elements passing
straight through connector modules 2130 such that contact tails
2134a and 2134b are in the same plane as mating contact portions
2132a and 2132b. In that configuration, module 2130 would be
mounted in housing 2126 with the side visible in FIG. 21B at a 45
degree angle with respect to the row and column directions.
[0204] Mounting connector modules 2130 with such a 45 degree
rotation with respect to the row or column direction may produce a
footprint similar to that shown in FIG. 8. However, each of the
mounting locations, such as mounting locations 194a and 194b, would
similarly be rotated 45 degrees with respect to the row and column
directions. In such a configuration, routing channels might be
created in the row direction, as illustrated, in FIG. 8. Rather
than routing channels in the column direction, routing channels
might extend at a 45 degree angle with respect to the row
direction.
[0205] Alternatively, connector modules 2130 might be configured to
provide a footprint as in FIG. 8. The mounting interface 2124 may
be configured like the mounting interface illustrated in FIG. 7,
for example. Such a mounting interface may be achieved by a 45
degree twist in the conductive elements passing through connector
modules 2130. In such an embodiment, the conductive elements may be
shaped with such a twist and inserted into a portion of a housing
with a groove similarly shaped to provide such a twist.
[0206] Modularity of components as described herein may support
other connector configurations using the same or similar
components. Those connectors may be readily configured to mate with
connectors as describe herein. FIG. 22, for example, illustrates a
modular connector in which some of the connector modules, rather
than having contact tails configured for mating with a printed
circuit board, are configured for terminating a cable, such as a
twin-ax cable. In the example of FIG. 22, a connector has a wafer
assembly 2204, a cabled wafer 2206 and a housing 2202. In this
example, cabled wafer 2206 may be positioned side-by-side with the
wafers in wafer assembly 2204 and inserted into housing 2202, in
the same way that wafers are inserted into a housing 110 or 120 to
provide a mating interface with receptacles or pins, respectively.
In alternative embodiments, the connector of FIG. 22 may be solely
a cable connector, such as by having only cabled wafers 2206, or
may be a hybrid-cable connector as shown with wafer assembly 2204
and cabled wafer 2206 side by side or, in some embodiments, with
some modules in the wafer having tails configured for attachment to
a printed circuit board and other modules having tails configured
for terminating a cable.
[0207] With a cabled configuration, signals passing through that
mating interface of the connector may be coupled to other
components within an electronic system including connector 2200.
Such an electronic system may include a printed circuit board to
which connector 2200 is mounted. Signals passing through the mating
interface in modules mounted to that printed circuit board may pass
over traces in the printed circuit board to other components also
mounted to that printed circuit board. Other signals, passing
through the mating interface in cabled modules may be routed
through the cables terminated to those modules to other components
in the system. In some system, the other end of those cables may be
connected to components on other printed circuit boards that cannot
be reached through traces in the printed circuit board.
[0208] In other systems, those cables may be connected to
components on the same printed circuit board to which the other
connector modules are mounted. Such a configuration may be useful
because connectors as described herein support signals with
frequencies that can be reliably passed through a printed circuit
board only over relatively short traces. High frequency signals,
such as signals conveying 56 or 112 Gbps, are attenuated
significantly in traces on the order of 6 inches long or more.
Accordingly, a system may be implemented in which a connector
mounted to a printed circuit board has cabled connector modules for
such high frequency signals, with the cables terminated to those
cabled connector modules also connected at the mid-board of the
printed circuit board, such as 6 or more inches from the edge or
other location on the printed circuit board at which the connector
is mounted.
[0209] In the example of FIG. 22, the pairs at the mating
interfaces are not rotated with respect to the row or column
direction. But a connector with one or more cabled wafers may be
implemented with rotation of the mating interface as described
above. For example, mating ends of the pairs of signal conductors
may be disposed at an angle of 45 degrees relative to mating row
and/or mating column directions. The mating column direction for a
connector may be a direction perpendicular to board mounting
interface, and the mating row direction may be the direction
parallel to the board mounting interface.
[0210] Further, it should be appreciated that, though FIG. 22 shows
that cabled connector modules are in only one wafer and all wafers
have only one type of connector module, neither is a limitation on
the modular techniques described herein. For example, the top row
or rows of connectors modules may be cabled connector modules while
the remaining rows may have connector modules configured for
mounting to a printed circuit board.
[0211] Additional exemplary embodiments of the technology described
herein are described further below.
[0212] In a first example, a connector module comprises a pair of
signal conductors, wherein the pair of signal conductors comprises
a pair of mating ends, a pair of contact tails and a pair of
intermediate portions connecting the pair of mating ends to the
pair of contact tails, the pair of mating ends are elongated in a
direction that is at a right angle relative to a direction in which
the pair of contact tails are elongated, the mating ends of the
pair of mating ends are separated in a direction of a first line,
the intermediate portions of the pair of intermediate portions are
separated in a direction of a second line, and the first line is
disposed at an angle greater than 0 degrees and less than 90
degrees relative to the second line.
[0213] The first line may be disposed at an angle greater than 30
degrees and less than 60 degrees relative to the second line.
[0214] The first line may be disposed at a 45 degree angle relative
to the second line.
[0215] The pair of signal conductors may further comprise a
transition region connecting the pair of intermediate portions and
the pair of mating ends, at which a first signal conductor of the
pair of signal conductors extends towards a third line along which
the pair of contact tails are separated, and a second signal
conductor of the pair of signal conductors extends away from the
third line.
[0216] The connector module may further comprises electromagnetic
shielding at least partially surrounding the mating ends of the
pair of signal conductors, and the electromagnetic shielding bounds
an area around the mating ends of less than 4.5 mm.sup.2.
[0217] The electromagnetic shielding may be embossed with an
outwardly projecting portion adjacent the transition region, so as
to offset changes in impedance along a length of the pair of signal
conductors associated with changes in shape of the pair of signal
conductors along the length.
[0218] The electromagnetic shielding may be further embossed with
an inwardly projecting portion adjacent the pair of mating ends so
as to reduce a disparity between a mated and partially demated
impedance of the connector module.
[0219] The electromagnetic shielding may comprise a pair of
electrically conductive shielding members, each of the electrically
conductive shielding members may comprise an intermediate portion
and a mating portion integral with the intermediate portion and a
transition between the mating portion and the intermediate portion,
and the transition may provide a twist in the shielding members at
the angle of the first line with respect to the second line.
[0220] The connector module may further comprise a first insulative
member supporting the pair of signal conductors, each mating end of
the pair of mating ends of the pair of signal conductors may
comprise a pair of mating arms separated by a gap, and the first
insulative member may comprise a portion extending beyond the pair
of mating ends and comprising a pair of apertures aligned with the
gaps.
[0221] The pair of mating ends may be configured to receive wires
through the pair of apertures and to retain the wires between the
pairs of mating arms.
[0222] The contact tails may be configured for inserting into holes
in a substrate.
[0223] The contact tails may be configured for inserting into holes
having a diameter of less than or equal to 20 mils.
[0224] The contact tails may each have a width between 6 and 20
mils.
[0225] The contact tails may be configured for inserting into holes
having a diameter of less than or equal to 10 mils.
[0226] The contact tails may each have a width between 6 and 10
mils.
[0227] The contact tails may be configured for making electrical
connection to pads of a substrate.
[0228] The transition region may comprise a 45 degree transition of
the pair of signal conductors over a length between 1.4 and 2
mm.
[0229] The connector module may further comprise an insulative
portion comprising a first side and a second side, the first side
comprises a first groove and the second side comprises a second
groove, and a first intermediate portion of the pair of
intermediate portions is disposed in the first groove and a second
intermediate portion of the pair of intermediate portions is
disposed in the second groove.
[0230] In a second example, a wafer may comprise a plurality of
signal conductor pairs, each signal conductor pair comprising a
pair of mating ends, a pair of contact tails and a pair of
intermediate portions connecting the pair of mating ends to the
pair of contact tails, the pairs of mating ends of the plurality of
signal conductor pairs are positioned in a column along a column
direction, the intermediate portions of the pairs of intermediate
portions of the plurality of signal conductor pairs are aligned in
a direction perpendicular to the column direction and positioned
for broadside coupling, and the mating ends of the plurality of
signal conductor pairs are separated along lines disposed at an
angle of greater than 0 degrees and less than 90 degrees relative
to the column direction.
[0231] The lines may be disposed at an angle of greater than 30
degrees and less than 60 degrees relative to the column
direction.
[0232] The lines may be disposed at an angle of 45 degrees relative
to the column direction.
[0233] The wafer may further comprise a housing supporting the
plurality of signal conductor pairs.
[0234] Each of the plurality of signal conductor pairs may comprise
a plurality of connector modules, each connector module of the
plurality of connector modules further comprised of electromagnetic
shielding disposed around the signal conductor pair, with portions
of the electromagnetic shielding at least partially surrounding the
mating ends of the signal conductors of the signal conductor pair
and being rectangular with a width less than 2 mm and a length less
than 3.8 mm.
[0235] The housing may comprise a first housing member comprising a
plurality of grooves, and a connector module of the plurality of
connector modules is disposed within a groove of the plurality of
grooves.
[0236] The housing may be formed of a lossy conductive
material.
[0237] The column direction may be a mating interface column
direction, the pairs of contact tails of the plurality of signal
conductor pairs are positioned in a column along a mounting
interface column direction, and contact tails of the pairs of
contact tails may be separated in a mounting interface row
direction perpendicular to the mounting interface column
direction.
[0238] The mating interface column direction may be orthogonal to
the mounting interface column direction.
[0239] The pairs of contact tails may be configured to be inserted
into holes having a diameter of less than or equal to 20 mils.
[0240] Each contact tail of the pairs of contact tails may have a
width between 6 and 20 mils.
[0241] The pairs of contact tails may be configured to be inserted
into holes having a diameter of less than or equal to 10 mils.
[0242] Each contact tail of the pairs of contact tails may have a
width between 6 and 10 mils.
[0243] Center-to-center spacing between adjacent pairs of contact
tails in the mounting interface column direction may be less than
or equal to 5 mm.
[0244] Center-to-center spacing between adjacent pairs of contact
tails in the mounting interface column direction may be less than
or equal to 2.4 mm.
[0245] The mounting interface row direction may be orthogonal to
the mounting interface column direction.
[0246] In a third example, a connector may comprise a plurality of
signal conductor pairs. For each signal conductor pair of the
plurality of signal conductor pairs, the signal conductor pair
comprises a pair of mating ends, a pair of contact tails, and a
pair of intermediate portions connecting the pair of mating ends to
the pair of contact tails, the signal conductor pair further
comprises a transition region between the pair of mating ends and
the pair of intermediate portions, the pairs of mating ends of the
plurality of signal conductor pairs are disposed in an array
comprising a plurality of rows, the plurality of rows extending
along a row direction and spaced from each other in a column
direction perpendicular to the row direction, the pairs of mating
ends of the plurality of signal conductor pairs are aligned along
first parallel lines that are disposed at an angle of greater than
0 degrees and less than 90 degrees relative to the row direction,
and, for each signal conductor pair of the plurality of signal
conductor pairs, within the transition region, a relative position
of the signal conductors of the signal conductor pair varies such
that, at a first end of the transition region adjacent the mating
end, the signal conductors are aligned along a line of the first
parallel lines and at a second end of the transition region the
signal conductors are aligned in the row direction.
[0247] The first parallel lines may be disposed at an angle of
greater than 30 degrees and less than 60 degrees relative to the
row direction.
[0248] The first parallel lines may be disposed at an angle of 45
degrees relative to the row direction.
[0249] Each pair of intermediate portions may be broadside coupled,
and wherein each pair of contact tails is broadside coupled.
[0250] The pairs of contact tails of the plurality of signal
conductor pairs may be arranged in a second array, and the second
array comprises columns of the pairs of contact tails extending
along a third direction.
[0251] The third direction may be orthogonal to the row
direction.
[0252] The third direction may be perpendicular to both of the
column direction and the row direction.
[0253] Each of the plurality of signal conductor pairs may further
comprise a second transition region, within the second transition
regions, a relative position of signal conductors of the signal
conductor pairs may vary such that, at a first end of the second
transition region adjacent the contact tails, the pair of signal
conductors are aligned along second parallel lines parallel to the
third direction, and, at a second end of the transition region
adjacent the intermediate portions, the pair of signal conductors
are aligned along third parallel lines disposed at an angle of
greater than 45 degrees and less than 135 degrees relative to the
third direction.
[0254] The second parallel lines may be disposed at an angle of
greater than 80 degrees and less than 100 degrees relative to the
third direction.
[0255] The second parallel lines may be perpendicular to the third
direction.
[0256] The second parallel lines may be parallel to the row
direction.
[0257] An electronic assembly may comprise the connector of the
third example in combination with a first printed circuit board
comprising a first edge, wherein the connector is a first connector
and the contact tails of the first connector are mounted to the
first printed circuit board adjacent the first edge, a second
printed circuit board, and a second connector mounted to the second
printed circuit board and configured for mating with the first
connector.
[0258] The contact tails of the first connector may be inserted
into holes of the first printed circuit board.
[0259] The contact tails of the first connector may be mounted to
pads on a surface of the first printed circuit board.
[0260] The contact tails of the first connector may be pressed into
holes of the first printed circuit board having unplated diameters
of less than or equal to 20 mils.
[0261] The contact tails of the first connector may have a width
between 6 and 20 mils.
[0262] The contact tails of the first connector may be pressed into
holes of the first printed circuit board having unplated diameters
between 6 and 12 mils.
[0263] The contact tails of the first connector may have a width
between 6 and 12 mils.
[0264] The first printed circuit board may comprise first and
second layers, traces fabricated on the first layer and extending
in a first direction may be connected to a first of the pairs of
contact tails of the first connector, and traces fabricated on the
second layer and extending in a second direction perpendicular to
the first direction may be connected to a second of the pairs of
contact tails of the first connector.
[0265] The second array may comprise the pairs of contact tails of
the first connector, the pairs of contact tails being disposed in a
repeating pattern with center-to-center spacing between adjacent
pairs of contact tails in the third direction of less than or equal
to 5 mm and center-to-center spacing between adjacent pairs of
contact tails in a direction perpendicular to the third direction
of less than or equal to 5 mm.
[0266] The second array may comprise the pairs of contact tails of
the first connector, the pairs of contact tails may be disposed in
a repeating pattern with center-to-center spacing between adjacent
pairs of contact tails in the third direction of less than or equal
to 2.4 mm and center-to-center spacing between adjacent pairs of
contact tails in a direction perpendicular to the third direction
of less than or equal to 2.4 mm.
[0267] The first printed circuit board may be perpendicular to the
second printed circuit board.
[0268] A surface of the second printed circuit board may face the
mating ends of the first connector.
[0269] The mating ends of the first connector may extend in a first
direction, the contact tails of the first connector may extend in a
second direction, and a surface of the second printed circuit board
may faces in a direction perpendicular to the first and second
directions.
[0270] The second connector may further comprise a plurality of
signal conductor pairs, each of the plurality of signal conductor
pairs may comprise a pair of mating ends, a pair of contact tails,
a pair of intermediate portions connecting the pair of mating ends
to the pair of contact tails, and a transition region between the
pair of mating ends and the pair of intermediate portions, the
mating ends of the plurality of signal conductor pairs may be
disposed in a first array comprising a plurality of rows, the
plurality of rows extending along the row direction and spaced from
each other in the column direction perpendicular to the row
direction, the signal conductors of the signal conductor pairs may
be aligned along first parallel lines that are disposed at an angle
of greater than 0 degrees and less than 90 degrees relative to the
row direction, and, within the transition regions, a relative
position of the signal conductors of the signal conductor pairs may
vary such that, at a first end of the transition region adjacent
the mating ends, the signal conductors are aligned along the first
parallel lines and at an end of the transition region the signal
conductors are aligned in the row direction.
[0271] The second connector may further comprise a plurality of
extender modules, each of the plurality of extender modules
comprising a pair of signal conductors each having first and second
portions, the second portions of the plurality of extender modules
are mounted to mating ends of the plurality of signal conductors of
the second connector, the first portions of the plurality of
extender modules are configured to be received in the mating ends
of the first connector, and the pairs of signal conductors of the
plurality of extender modules are each elongated in a straight line
from the first portions to the second portions.
[0272] The electronic assembly may be further configured to
transmit data from the first connector to the second connector at a
rate of approximately 112 Gb/s.
[0273] The electronic assembly may be further configured to operate
with a bandwidth of approximately 50-60 GHz.
[0274] In a fourth example, a connector module comprises an
insulative member and a pair of signal conductors held by the
insulative member, wherein each signal conductor of the pair of
signal conductors comprises a first portion at a first end, a
second portion at a second end extending from the insulative
portion and an intermediate portion disposed between the first and
second ends, and the first portion comprises a wire with a diameter
between 5 and 20 mils.
[0275] The wire may be a superelastic wire.
[0276] The superelastic wire of each signal conductor of the pair
of signal conductors may be brazed to the intermediate portion of
the signal conductor.
[0277] The connector module may further comprise electromagnetic
shielding at least partially surrounding the intermediate portions
of the pair of signal conductors, and the electromagnetic shielding
bounds an area around the first portions of less than 4.5
mm.sup.2.
[0278] The electromagnetic shielding may be embossed with an
outwardly projecting portion adjacent the first ends, so as to
offset changes in impedance along a length of the pair of signal
conductors associated with changes in shape of the pair of signal
conductors along the length.
[0279] The electromagnetic shielding member may be further embossed
with an inwardly projecting portion adjacent distal ends of the
first portions so as to reduce a disparity between a fully mated
and a partially demated impedance of the connector module.
[0280] The electromagnetic shielding member may comprise
electrically conductive shielding.
[0281] The second portions may comprise superelastic wires with a
width between 5 and 20 mils.
[0282] The diameter of the superelastic wires may be less than 12
mils.
[0283] The superelastic wires may be configured for inserting into
a hole having a diameter of less than or equal to 10 mils.
[0284] A mating force of the superelastic wires may be between 25
and 45 gm.
[0285] A mating force of the superelastic wires may be between 30
and 40 gm.
[0286] The second portions may comprise press-fit members.
[0287] Cross sections of the press-fit members may have a
serpentine shape.
[0288] An electrical connector may comprise a plurality of the
connector modules disposed in a plurality of parallel rows,
extending in a row direction.
[0289] An impedance change between fully mated and partially
demated configurations of the first portions may be less than 5
Ohms at 20 GHz.
[0290] Second portions of the connector modules of the plurality of
connector modules may comprise contact tails, pairs of the contact
tails being disposed in a second plurality of rows extending in a
first direction and positioned along a second direction
perpendicular to the first direction in a repeating pattern with
center-to-center spacing between adjacent pairs of contact tails in
the first direction of less than or equal to 2.5 mm and
center-to-center spacing between adjacent pairs of contact tails in
the second direction perpendicular to the first direction of less
than or equal to 2.5 mm.
[0291] Second portions of the plurality of connector modules may
comprise contact tails, pairs of the contact tails being disposed
in a second plurality of rows extending in a first direction and
positioned along a second direction perpendicular to the first
direction in a repeating pattern with center-to-center spacing
between adjacent pairs of contact tails in the first direction of
less than or equal to 2.4 mm and center-to-center spacing between
adjacent pairs of contact tails in the second direction
perpendicular to the first direction of less than or equal to 2.4
mm.
[0292] First portions of each signal conductor pair of the
plurality of connector modules may be aligned along first parallel
lines disposed at a 45 degree angle with respect to the row
direction.
[0293] An overall impedance of each connector module may be between
90 ohms and 100 ohms over the range of 45-50 GHz.
[0294] In a fifth example, an extender module comprises a pair of
signal conductors, each signal conductor of the pair of signal
conductors comprising a first portion at a first end and a second
portion at a second end and electromagnetic shielding at least
partially surrounding the pair of signal conductors, the first
portions of the pair of signal conductors are configured as mating
portions and are positioned along a first line, and the second
portions of the pair of signal conductors are configured to
compress upon insertion into a hole and are positioned along a
second line parallel to the first line.
[0295] The electromagnetic shielding may comprise electrically
conductive shielding.
[0296] The second portions may be "S" shaped in cross-section.
[0297] The second portions may be configured for insertion into
interface holes having a diameter of less than or equal to 20
mils.
[0298] The second portions may have a width between 6 and 20
mils.
[0299] The second portions may be configured for inserting into
interface holes having a diameter of less than or equal to 10
mils.
[0300] The second portions may have a width between 6 and 10
mils.
[0301] A connector may comprise an insulative portion and plurality
of signal conductors supported by the insulative portion, each of
the plurality of signal conductors having a mating portion bounding
an interface hole, and a plurality of the extender modules, the
second portions of the signal conductors of the extender modules
being inserted into the interface holes.
[0302] The plurality of extender modules may further comprise a
plurality of signal conductor pairs having pairs of second portions
each aligned along first parallel lines, the plurality of signal
conductors further comprises a plurality of signal conductor pairs
having pairs of intermediate portions and pairs of mating portions
connected by transition regions, signal conductors of each signal
conductor pair are aligned along the first parallel lines at a
first portion of the transition region adjacent the pair of mating
portions, and the signal conductors are aligned along second
parallel lines disposed at a 45 degree angle relative to the first
parallel lines at a second portion of the transition region
adjacent the pair of intermediate portions.
[0303] In a sixth example, a connector comprises an insulative
portion, a plurality of signal conductors held by the insulative
portion, and a plurality of shielding members, the plurality of
signal conductors comprise elongated mating portions extending from
the insulative portion, the plurality of signal conductors comprise
a plurality of pairs of signal conductors disposed in a plurality
of rows extending in a row direction, the plurality of shielding
members at least partially surround pairs of the plurality of
pairs, and the mating portions of the plurality of pairs are
separated along first parallel lines disposed an angle of 45
degrees relative to the row direction.
[0304] The plurality of shielding members may comprise electrically
conductive shielding.
[0305] The insulative portion may comprise a planar portion having
a first surface and a second surface, opposite the first surface,
the mating portions extend in a direction perpendicular to the
first surface, and the signal conductors further comprise tails
that extend through the second surface.
[0306] The contact tails may be disposed in a second plurality of
rows extending in a first direction and positioned along a second
direction perpendicular to the first direction in a repeating
pattern with center-to-center spacing between adjacent pairs of
contact tails in the first direction of less than or equal to 5 mm
and center-to-center spacing between adjacent pairs of contact
tails in the second direction perpendicular to the first direction
of less than or equal to 5 mm.
[0307] The contact tails may be disposed in a second plurality of
rows extending in a first direction and positioned along a second
direction perpendicular to the first direction in a repeating
pattern with center-to-center spacing between adjacent pairs of
contact tails in the first direction of less than or equal to 2.4
mm and center-to-center spacing between adjacent pairs of contact
tails in the second direction perpendicular to the first direction
of less than or equal to 2.4 mm.
[0308] The contact tails may be configured for inserting into holes
having a diameter of less than or equal to 20 mils.
[0309] The contact tails may have a width of between 6 and 20
mils.
[0310] The contact tails may be configured for inserting into holes
having a diameter of less than or equal to 10 mils.
[0311] The contact tails may have a width of between 6 and 10
mils.
[0312] The plurality of pairs of signal conductors may further
comprise intermediate portions connected to the mating portions by
transition regions, signal conductors of each pair of signal
conductors are separated along the first parallel lines at a first
portion of the transition region adjacent the mating portions, and
the signal conductors may be separated along second parallel lines
parallel to the row direction at a second portion of the transition
region adjacent the intermediate portions.
[0313] It should be appreciated that aspects of each of the above
described examples may be combined in a single embodiment. Further,
optional aspects of each of the examples may be used alone or in
combination.
[0314] Having thus described several aspects of at least one
embodiment of this invention, it is to be appreciated that various
alterations, modifications, and improvements will readily occur to
those skilled in the art.
[0315] For example, FIG. 23 illustrates a pair of signal conductors
260' that has an angled mating interface, as described above in
connection with signal conductors 260. Like signal conductors 260,
signal conductors 260' have intermediate portions 264a' and 264b'
that are broadside coupled. Unlike signal conductors 260, signal
conductors 260' have broadside coupled contact tails 266a' and
266b', which are separated along line 144', which parallel to the
row direction of the board mounting interface of a connector
including signal conductors 260'. Signal conductors as shown in
FIG. 23, may be incorporated into a connector using techniques as
described herein.
[0316] For example, signal conductors 260a and 260b are described
as being configured for carrying a differential signal. In other
embodiments, modules 200 may contain conductors configured to carry
a single ended electrical signal. For example, one signal conductor
may carry a signal and the other may be grounded. Alternatively, in
some embodiments, a single signal conductor may be used in place of
a pair of signal conductors 260a and 260b in some embodiments with
the ground reference carried by the electromagnetic shielding.
[0317] As another example, it is described that extender modules
300 are attached to connector modules using press fit connections.
Other forms of attachment may be use, including separable contacts
that are the same at both ends of the extender module or other
forms of fixed attachment, such as soldering or brazing.
[0318] Further, electrical connectors 102a-d described herein may
be adapted for any suitable configuration such as backplane or
midplane. For example, in a backplane configuration, first
connector 102a and second connector 102b may mate along a same
direction which one of first contact tail array 136a and second
contact tail array 136b faces and which the other one faces
opposite. Alternatively, surfaces of substrate 104c onto which
first contact tail array 136a is mounted and of a substrate 104d
onto which second contact tail array 136b is mounted may be
parallel to one another. In a further configuration, first contact
tail array 136a and second contact tail array 136b may face a first
direction, with first and second connectors 102a and 102b
configured to mate along a direction perpendicular to the first
direction.
[0319] It should be appreciated that, in some embodiments,
connector module 200 may include a single insulative member rather
than having separate outer insulative members 280a and 280b and
inner insulative member 230. In some embodiments, connector module
200 includes one insulative member in place of outer insulative
members 280a and 280b, and also includes inner insulative member
230. In some embodiments, a dielectric constant of outer insulative
members 280a and 280b may differ from that of inner insulative
member 230. Alternatively, outer insulative members 280a and 280b
and inner insulative member 230 have substantially a same
dielectric constant.
[0320] It should be appreciated that, rather than compliant
receptacles 270a and 270b, mating ends 262 may include alternative
mating components, such as pins, compliant beams or wires.
Likewise, contact tails 266a and 266b may be alternatively
configured for mounting in other ways than press fit, such as to
conductive pads on a surface of a printed circuit board.
[0321] As yet another example, transition regions were described in
which there is a twist of either 45 or 90 degrees. Other amounts of
twist are possible in the transition regions. In some embodiments,
parallel lines 138 are disposed at an angle of greater than 0
degrees and less than 90 degrees relative to mating row direction
142 or mating column direction 140. In some embodiments, parallel
lines 138 are disposed at an angle of greater than 30 degrees and
less than 60 degrees relative to mating row direction 142 or mating
row direction 140. In some embodiments, parallel lines 138 are
parallel to mating column direction 140 or mating row direction
142.
[0322] Likewise, in some embodiments, contact tail row direction
146 may be disposed at an angle greater than 45 degrees and less
than 135 degrees relative to contact tail column direction 144. In
some embodiments, contact tail row direction 146 may be disposed at
an angle greater than 80 degrees and less than 100 degrees relative
to contact tail column direction 144. In the illustrated
embodiment, contact tail row direction 146 is perpendicular to
contact tail column direction 144. However, in some embodiments,
contact tail row direction 146 is parallel to contact tail column
direction 144.
[0323] Moreover, the twist in each of two mating connectors may be
the same, or may be different in angular amount. Further, the twist
in each of two mating connectors may be in the same direction or in
opposite directions. For example, in the embodiment illustrated in
FIG. 16A, the twist is in a clockwise direction from the contact
tails 266a and 266b to intermediate portions 264a and 264b. The
twist is again in the clockwise direction from intermediate
portions 264a and 264b to mating ends 262a and 262b. Either or both
such twists may be in a counterclockwise direction, and the
direction of twist in each transition region 268a and/or 268b may
be the same or different in mating connectors. For example, the
twist in the transition region 268a from intermediate portions 264a
and 264b to mating ends 262a and 262b may be opposite in each of
two mating connectors to support parallel board connector
configurations.
[0324] As an example of a further variation, pairs of signal
conductors could be configured without any twist in the pairs. The
mating interfaces of each pair may be at an angle, such as 45
degrees, with respect to the mating interface row direction. The
tails of each pair may be at the same angle with respect to the
mounting interface row direction. Such a configuration may be used
in a mezzanine, or other suitable style of connector, and may
enable the footprint for the connector to occupy less surface area
of a printed circuit board to which the connector is mounted.
[0325] It should be appreciated that, in some embodiments, contact
tails of third contact tail array 136c are configured for inserting
into holes having a diameter of less than or equal to 20 mils. In
some embodiments, contact tails of third contact tail array 136c
are configured for inserting into holes having a diameter of less
than or equal to 10 mils. In some embodiments, contact tails of
third contact tail array 136c each have a width between 6 and 20
mils. In some embodiments, contact tails of third contact tail
array 136c each have a width between 6 and 10 mils.
[0326] As a further example of a possible variation, extender
module 300 was illustrated with two electromagnetic shielding
members that cover two opposing sides of the module. Alternatively,
electromagnetic shielding may be implemented with a shielding
member that covers, or partially covers, 3 sides or all 4 sides of
the module. In some embodiments, the electromagnetic shielding
member partially covers some or all sides with a gap on the
partially covered side(s). Such shielding configurations may be
implemented with one or more shielding members.
[0327] As another possible variation, it should be appreciated
that, while some embodiments described herein include second
portions 306a and 306b of extender module 300 implemented by
contact tails, in some embodiments second portions 306a and 306b
may be shaped like mating portions 304a and 304b. The mating
portions may include pins configured to extend through apertures of
extended portion 234 and may be sized to fit between arms 272a and
272b of compliant receptacles 270a and 270b such that the pins may
be removed from compliant receptacles 270a and 270b without damage
to either connector.
[0328] Such alterations, modifications, and improvements are
intended to be part of this disclosure, and are intended to be
within the spirit and scope of the invention. Further, though
advantages of the present invention are indicated, it should be
appreciated that not every embodiment of the invention will include
every described advantage. Some embodiments may not implement any
features described as advantageous herein and in some instances.
Accordingly, the foregoing description and drawings are by way of
example only.
[0329] Various aspects of the present invention may be used alone,
in combination, or in a variety of arrangements not specifically
discussed in the embodiments described in the foregoing and is
therefore not limited in its application to the details and
arrangement of components set forth in the foregoing description or
illustrated in the drawings. For example, aspects described in one
embodiment may be combined in any manner with aspects described in
other embodiments.
[0330] Also, the invention may be embodied as a method, of which an
example has been provided. The acts performed as part of the method
may be ordered in any suitable way. Accordingly, embodiments may be
constructed in which acts are performed in an order different than
illustrated, which may include performing some acts simultaneously,
even though shown as sequential acts in illustrative
embodiments.
[0331] Use of ordinal terms such as "first," "second," "third,"
etc., in the claims to modify a claim element does not by itself
connote any priority, precedence, or order of one claim element
over another or the temporal order in which acts of a method are
performed, but are used merely as labels to distinguish one claim
element having a certain name from another element having a same
name (but for use of the ordinal term) to distinguish the claim
elements.
[0332] All definitions, as defined and used herein, should be
understood to control over dictionary definitions, definitions in
documents incorporated by reference, and/or ordinary meanings of
the defined terms.
[0333] The indefinite articles "a" and "an," as used herein in the
specification and in the claims, unless clearly indicated to the
contrary, should be understood to mean "at least one."
[0334] As used herein in the specification and in the claims, the
phrase "at least one," in reference to a list of one or more
elements, should be understood to mean at least one element
selected from any one or more of the elements in the list of
elements, but not necessarily including at least one of each and
every element specifically listed within the list of elements and
not excluding any combinations of elements in the list of elements.
This definition also allows that elements may optionally be present
other than the elements specifically identified within the list of
elements to which the phrase "at least one" refers, whether related
or unrelated to those elements specifically identified.
[0335] The phrase "and/or," as used herein in the specification and
in the claims, should be understood to mean "either or both" of the
elements so conjoined, i.e., elements that are conjunctively
present in some cases and disjunctively present in other cases.
Multiple elements listed with "and/or" should be construed in the
same fashion, i.e., "one or more" of the elements so conjoined.
Other elements may optionally be present other than the elements
specifically identified by the "and/or" clause, whether related or
unrelated to those elements specifically identified. Thus, as a
non-limiting example, a reference to "A and/or B", when used in
conjunction with open-ended language such as "comprising" can
refer, in one embodiment, to A only (optionally including elements
other than B); in another embodiment, to B only (optionally
including elements other than A); in yet another embodiment, to
both A and B (optionally including other elements); etc.
[0336] As used herein in the specification and in the claims, "or"
should be understood to have the same meaning as "and/or" as
defined above. For example, when separating items in a list, "or"
or "and/or" shall be interpreted as being inclusive, i.e., the
inclusion of at least one, but also including more than one, of a
number or list of elements, and, optionally, additional unlisted
items. Only terms clearly indicated to the contrary, such as "only
one of" or "exactly one of," or, when used in the claims,
"consisting of," will refer to the inclusion of exactly one element
of a number or list of elements. In general, the term "or" as used
herein shall only be interpreted as indicating exclusive
alternatives (i.e. "one or the other but not both") when preceded
by terms of exclusivity, such as "either," "one of," "only one of,"
or "exactly one of." "Consisting essentially of," when used in the
claims, shall have its ordinary meaning as used in the field of
patent law.
[0337] Also, the phraseology and terminology used herein is for the
purpose of description and should not be regarded as limiting. The
use of "including," "comprising," or "having," "containing,"
"involving," and variations thereof herein, is meant to encompass
the items listed thereafter and equivalents thereof as well as
additional items.
* * * * *